Crosslinkable composition without antioxidant and beneficial methane formation with reduced crosslinking

ABSTRACT

The invention relates to a polymer composition comprising a polyethylene and a crosslinking agent, characterized in that the polymer composition contains a total amount of vinyl groups which is B vinyl groups per 1000 carbon atoms, and B1≤B, wherein B1 is 0.88, when measured prior to crosslinking according to method ASTM D6248-98; and in that the crosslinking agent is present in an amount which is Z wt %, based on the total amount (100 wt %) of the polymer composition, and Z≤Z2, wherein Z2 is 0.30, an article being e.g. a cable, e.g. a power cable, and processes for producing a polymer composition and an article; useful in different end applications, such as wire and cable (W&amp;C) applications.

FIELD OF INVENTION

The invention relates to a polymer composition comprising a polyethylene and a crosslinking agent, an article comprising layer(s), e.g. insulating layer(s), which is/are obtained from the polymer composition, the article may be a cable, e.g. a power cable, processes for producing the polymer composition and the article which comprises use of a polymer composition. Further, the polymer composition may be useful in different end applications, such as wire and cable (W&C) applications, especially in cable applications, such as power cable applications, e.g., in medium voltage (MV) and, for example, in high voltage (HV) and, for example, e.g., extra high voltage (EHV) cable applications. Further, the polymer composition may be useful in both alternating current (AC) and direct current (DC) applications.

BACKGROUND ART

Polyethylenes produced in a high pressure (HP) process are widely used in demanding polymer applications wherein the polymers must meet high mechanical and/or electrical requirements. For instance in W&C applications, e.g. power cable applications, e.g., in low voltage (LV), MV, HV, and EHV applications, the mechanical and the electrical properties of polyethylenes, and of polymer compositions comprising polyethylenes, have significant importance.

For instance in power cable applications, particularly in MV and especially in HV, and EHV cable applications, the electrical properties of the polymer composition have a significant importance. Furthermore, the electrical properties, which are of importance, may differ in different cable applications, as is the case between AC and DC cable applications.

Further, it is also known that crosslinking of polymers, e.g. polyethylenes, substantially contributes to an improved heat and deformation resistance, mechanical strength, chemical resistance and abrasion resistance of a polymer. Therefore crosslinked polymers are widely used in different end applications, such as in the mentioned W&C applications.

Furthermore, in cable applications, an electric conductor is usually coated first with an inner semiconducting layer, followed by an insulating layer and an outer semiconducting layer. To these layers, further layer(s) may be added, such as screen(s) and/or auxiliary barrier layer(s), e.g. one or more water barrier layer(s) and one or more jacketing layer(s).

Due to benefits, mentioned herein, which are achievable with crosslinking, the insulating layer and the semiconducting layers in cable applications are typically made using crosslinkable polymer compositions. The polymer compositions in a formed layered cable application are then crosslinked.

Furthermore, such crosslinkable polymer compositions comprising low density polyethylene (LDPE), are today among the predominant cable insulating materials for power cables.

The crosslinking can be performed with crosslinking agents where the crosslinking agents decompose generating free radicals. Such crosslinking agents, e.g. peroxides, are conventionally added to the polymeric material prior to, or during, the extrusion of the cable. Said crosslinking agent should preferably remain stable during the extrusion step. The extrusion step should preferably be performed at a temperature low enough to minimize the early decomposition of the crosslinking agent, but high enough to obtain proper melting and homogenisation of the polymer composition. If a significant amount of crosslinking agent, e.g. peroxide, decomposes already in the extruder, and thereby initiates premature crosslinking, it will result in formation of, so-called, “scorch”, i.e. inhomogeneity, surface unevenness and possibly discolouration in the different layers of the resultant cable. Therefore, any significant decomposition of crosslinking agents, i.e. free radical forming agents, during extrusion should be avoided. Instead, the crosslinking agents should ideally decompose merely in a subsequent crosslinking step at elevated temperature. The elevated temperature will increase the decomposition rate of the crosslinking agents and will thus increase crosslinking speed, and a desired, i.e. a target, crosslinking degree may be reached faster.

Moreover, when a polymer composition in, for example, a cable, is crosslinked, the decomposition of the crosslinking agents, e.g. peroxides, during the crosslinking, will further also result in formation of peroxide decomposition products. Some of the peroxide decomposition products are volatile, and their main component is methane if the types of peroxides that typically are used for crosslinking in relation to, for example, a cable, are used. The peroxide decomposition products remain mostly captured within the polymer composition of, for example, a cable, after crosslinking. This causes, e.g. problems in view of the cable manufacturing process as well as in view of the quality of the final cable.

Especially MV, HV and EHV power cables must have layers of high quality in order to help safety during installation and in end uses of said cables. In installation, for example, it is of importance to avoid that captured decomposition products e.g. flammable methane, ingnite, for example when end caps are removed. In service, volatile peroxide decomposition products formed in a cable during a crosslinking step can create a gas pressure and thus cause defects in the shielding and in the joints. E.g. when a cable core is equipped with a metal barrier, then the gaseous products can exert a pressure, especially on the joints and terminations, whereby a system failure may occur. Thus, the level of these volatile peroxide decomposition products needs to be reduced, to a low enough level, before subsequent cable production steps can take place.

A low enough level of the volatile peroxide decomposition products renders a use of the polymer composition comprising LDPE safe for use in installations, such as cable installations, and with accessories, such as cable accessories. Thus, today a, so called, degassing step, which reduces the level of volatile peroxide decomposition products, is needed in cable production process. The degassing step is a time and energy consuming and thus costly operation in a cable manufacturing process. Degassing requires large heated chambers which must be well ventilated to avoid the build-up of e.g. flammable methane. The cable core, i.e. layers and conductor, typically wound onto cable drums, is normally held in said degassing step in elevated temperature in the range of 50−80° C., e.g. 60-70° C., for lengthy time periods. When exposed to the required temperatures thermal expansion and softening of the insulation can occur and lead to unwanted deformation of the formed cable layers resulting directly to failures of the cable. The degassing of HV, and EHV cables with high cable weight needs thus often to be carried out at decreased temperatures which prolongs the degassing time further. Accordingly, there is a need to find new solutions to overcome the problems of the state of the art.

Further, the crosslinking of a polymer composition, comprised, in, for example, a cable, substantially contributes, to the improved heat and deformation resistance, mechanical strength, chemical resistance and abrasion resistance of the polymer composition and the cable comprising the polymer composition.

In this context see U.S. Pat. No. 5,539,075, which relates to a method of producing an unsaturated copolymer of ethylene and at least one monomer, wherein the monomer is a polyunsaturated compound and copolymerisable with ethylene.

See also EP2318210B1, which relates to a polymer composition comprising an unsaturated LDPE copolymer of ethylene with one or more polyunsaturated comonomers and being suitable for crosslinked polymer applications. The polymer composition has a melt flow rate under 2.16 kg load, MFR₂, of at least 2.8 g/10 min, and contains carbon-carbon double bonds in an amount of at least 0.40 carbon-carbon double bonds/1 000 carbon atoms.

Additionally, different materials, i.e. polymer compositions, may be needed for different cables, cable constructions and lines. Moreover, it is not possible to run all cables or cable constructions on all cable lines using, a, herein so called, standard viscosity “crosslinked” (here, more correctly, meaning “crosslinkable”) polyethylene (XLPE) materials having melt flow rate under 2.16 kg load, MFR₂, values around 2 g/10 min. That is because of that these standard viscosity XLPE materials do not have sufficient sagging resistance. The insufficiency in sagging resistance is normally solved, in the case of a cable, by using materials with MFR₂ values lower than 2 g/10 min. Materials, which have MFR₂ values lower than 2 g/10 min, have high viscosity and improved sagging resistance. The improved sagging resistance is needed for big cable constructions and for cable production in catenary cable lines, as well as, for cable production in horizontal cable lines. For example, in horizontal continuous vulcanization lines, e.g. a Mitsubishi Dainichi Continuous Vulcanization (MDCV) line, and in catenary continuous vulcanization (CCV) lines (especially for thicker constructions) for producing cables, it is typically required to use polymeric materials, e.g., for insulation layers, which have lower MFR₂ compared to the MFR₂ of polymeric materials (e.g. standard viscosity XLPE materials) used in vertical continuous vulcanization (VCV) lines and CCV lines (for thinner constructions).

In horizontal continuous vulcanization lines for producing cables, the conductor may sink within the insulation layer, if polymeric materials which have a too high MFR₂ are used, the sinking of the conductor may also result in an eccentricity of the cable core.

Likewise in CCV lines, if polymeric materials which have a too high MFR₂, i.e. also having a too low sagging resistance, are used, the wall thickness may become too large as soft molten polymeric material of an insulation layer may drop off the conductor. This will result in a downward displacement of the insulation layer, thus rendering an eccentricity, e.g. a, so called, pear shaped cable core.

Further, the insufficiency in the sagging resistance may be counteracted by different methods, such as:

using eccentric tools in the extruder head to compensate for the effect of sinking of the conductor;

twisting of the cable core to counter act displacement of the conductor, using of a double rotating technique to counteract the pear shaping, and, also, using a, so-called, entry heat treatment (EHT).

Accordingly, polymeric materials having a comparably lower MFR₂ and higher viscosity, as already described, are normally used to counteract these sagging behaviors.

However, materials having high viscosity will generate a higher melt temperature at commonly used extrusion conditions which may lead to higher risk for premature crosslinking and, thus, formation of prematurely crosslinked matter, i.e. “scorch”. “Scorch” may, as already described herein, be inhomogeneity, surface unevenness and/or possibly discolouration in the different layers of, for example, the resulting cable. The formation of “scorch” may have severe impact on productivities in the cable lines, as it significantly limits the production length before cleaning is needed and therefore the production rate is reduced. Thus, when producing a cable, by using polymeric materials having a lower MFR₂ generating a higher temperature in the melt, a lower production speed is required to reduce the melt temperature and thereby minimizing “scorch”.

Accordingly, a drawback with decreasing the MFR₂ value of a material may thus be that it also requires changes in processing conditions such as the lowering of the production speed.

The processing conditions are, besides the sagging resistance, also properties that are of importance in relation to crosslinkable XLPE materials, such as peroxide crosslinkable XLPE materials. Ideally, the material shall have low viscosity under the extrusion step of the process in order to have an, under the extrusion step, desirably low melt temperature. On the other hand, in the crosslinking step of the process a comparably higher viscosity of the material may be desirable. If a crosslinkable XLPE material generates a low melt temperature, there is less risk for “scorch” formation during an extrusion of, e.g., a cable construction, as compared with an extrusion involving another crosslinkable XLPE material generating a higher temperature in the melt.

The sagging resistance and the viscosity under processing conditions may both be visualised by viscosity curves obtained in plate-plate rheology measurements. Said sagging resistance is, then, visualised via the complex viscosity (η*) at very low shear rates, i.e. η*₀ and η*_(0.05) at 0 rad/sec and 0.05 rad/sec, respectively, and said viscosity under processing conditions is, then, visualised via the complex viscosity η*₃₀₀ at 300 rad/sec.

Still a further important property for XLPE is the crosslinking degree where the target crosslinking degree level shall be reached with, ideally, as low amount of crosslinking agent, such as peroxide, as possible. The degree of crosslinking may, for example, be measured with the, so-called, hot set test. In accordance with said hot set test, the lower the hot set elongation value, the more crosslinked is the material. An, as low as possible, amount of the crosslinking agent reduces the volatile peroxide decomposition products and also reduces time needed for degassing.

The extrusion and the crosslinking steps of a polymeric material included in, for example, cable production have different requirements. The critical parameter for the extrusion step is, as already described, that the polymeric material generates a low melt temperature in order to reduce the risk for “scorch”. This is influenced by the rheological properties in the region of shear rate that the polymeric material is exhibiting in the extruder, for example, using a low complex viscosity (η*) at 300 rad/sec. A low complex viscosity (η*) at 300 rad/sec is generally connected to a polymeric material having a higher melt flow rate (MFR₂).

However, an increase in melt flow rate must often be balanced as a polymeric material with a high MFR₂ has a too low sagging resistance which will result in, for example, a non-centric cable, which is not acceptable. The rheological property that is influencing the sagging resistance is the complex viscosity (η*) at very low shear rates, such as, at 0 rad/sec. However, the complex viscosity (η*) at 0 rad/sec is an extrapolated value, and thus here a measured complex viscosity (η*) at 0.05 rad/sec is used instead.

Accordingly, there is a need to find new solutions to overcome the problems of the state of the art.

DESCRIPTION OF THE INVENTION

The present invention relates to a polymer composition comprising a polyethylene and a crosslinking agent, wherein the polymer composition contains a total amount of vinyl groups which is B vinyl groups per 1000 carbon atoms, and B₁≤B, wherein B₁ is 0.88, when measured prior to crosslinking according to method ASTM D6248-98; and the crosslinking agent is present in an amount which is Z wt %, based on the total amount (100 wt %) of the polymer composition, and Z≤Z₂, wherein Z₂ is 0.30.

In one embodiment, the inventors have found that the combination of the above-mentioned features with a relatively low MFR₂ surprisingly leads to a polymer composition with attractive properties as discussed below.

The polymer composition according to the present invention which contains the comparably higher total amount of vinyl groups, B, as defined herein, surprisingly combines, in one polymer composition:

good processability, e.g. a good flowability, which is generally only associated with materials having a comparably higher MFR₂, with

excellent sagging resistance generally only associated with materials having a comparably lower MFR₂, and

exhibition of surprisingly low methane levels, with

a technically desirable level of crosslinking degree maintained.

Further, that the polymer composition combines excellent sagging resistance with good processability, e.g. flowability, is also illustrated by the fact that the polymer composition exhibits balanced complex viscosities (η*) at 300 rad/sec and at 0.05 rad/sec, both complex viscosities (η*) are determined prior to crosslinking according to method ISO 6721-1 on stabilised samples of the polyethylene. The complex viscosity (η*) at 300 rad/sec is accordingly low, and the complex viscosity (η*) at 0.05 rad/sec is accordingly high, which results in a polymer composition, according to the present invention, which has improved processing properties in an extruder, and which still allows generation of a cable, including big cable constructions, with good centricity in cable production for all types of cable lines. Such cables, comprising layers, e.g. insulation layers, being obtained from the polymer composition, may thus accordingly be produced.

Moreover, the polymer composition, according to the present invention, has unexpectedly also been shown to exhibit surprisingly low methane levels, while, at the same time, a technically desirable level of crosslinking degree, of the polymer composition, is maintained using a relatively low amount of the crosslinking agent, i.e. Z wt %, as defined herein. The technically desirable level of crosslinking degree insures sufficient thermo-mechanical properties, e.g. maintaining dimensional stability at elevated temperature. The crosslinking agent may, e.g., be peroxides which are well known in the art. The amount of formed volatile decomposition products, wherein the main component typically is methane, depends directly on the amount of crosslinking agent, e.g., peroxide, being added to the polymer composition. For any given crosslinking agent, e.g. peroxide, the amount of formed volatile decomposition products further also depends on the chemical structure of the crosslinking agent. Further, by selecting said relatively low amount of the crosslinking agent, while the desirable level of crosslinking degree of a polymer composition is maintained, a polymer composition exhibiting low methane levels, as well as, retaining a memory effect when crosslinked, is enabled.

Said low methane levels allow for shorter degassing time or, alternatively, make the degassing step completely redundant, both alternatives being much beneficial for the overall production of crosslinkable and crosslinked articles, for example cables, comprising layer/s, e.g. an insulation layer, obtained from the polymer composition.

Thus, the polymer composition comprising the polyethylene of the present invention is clearly highly advantageous to be used in production of crosslinkable and crosslinked articles, for example cables, e.g. cable layers thereof, for example, cable insulation layers.

The polymer composition is crosslinkable and is highly suitable for producing crosslinkable articles, e.g. one or more crosslinkable layers of a cable, for example one or more crosslinkable insulation layers, of a cable, which layers are subsequently crosslinked.

Furthermore, the polymer composition according to the present invention is suitable for W&C applications, e.g. AC, HVAC, DC and HVDC applications, and is especially suitable for DC and HVDC applications.

“Crosslinkable” is a well known expression and means that the polymer composition can be crosslinked, e.g. via radical formation, to form bridges i.a. amongst the polymer chains.

The polymer composition comprises a polyethylene and a crosslinking agent.

The polyethylene will be described in detail under the section “The polyethylene of the polymer composition”.

The polyethylene comprised in the polymer composition of the present invention may be unsaturated or saturated.

A further embodiment of the present invention is provided wherein the polyethylene is saturated.

Note that the wordings “embodiment” or “embodiments”, even if standing alone herein, always relate embodiment of the present invention or embodiments of the present invention.

In a further embodiment there is provided a polymer composition of the present invention which comprises a polyethylene, wherein the polyethylene is unsaturated.

That the polyethylene is “unsaturated” means herein that the polyethylene comprises carbon carbon double bonds. Carbon carbon double bonds mean herein unsaturations. The polyethylene, as described herein, comprises vinyl groups, for example, allyl groups. Vinyl groups are functional groups which comprise carbon carbon double bonds. The term “vinyl group” as used herein takes is conventional meaning, i.e. the moiety “—CH═CH2”. Further, the polyethylene may in addition comprise other functional groups also comprising carbon carbon double bonds. The other functional groups, also comprising carbon carbon double bonds, may be, e.g., vinylidene groups and/or vinylene groups. The vinylene group has either a cis or trans configuration. For the avoidance of doubt, vinylidene groups and vinylene groups are not vinyl groups as the terms are used herein.

Said “total amount of vinyl groups which is B vinyl groups per 1000 carbon atoms” means the “total amount of vinyl groups which is B vinyl groups per 1000 carbon atoms” present in the polymer composition when measured prior to crosslinking in accordance with the present invention. Further, at least the polyethylene contains said vinyl groups which contribute to the total amount of vinyl groups.

The polymer composition may optionally comprise further component(s) containing vinyl groups, which then also contribute to the total amount of said vinyl groups. In an embodiment therefore, the vinyl group content is thus measured on the polymer composition as a whole and not just on the polyethylene thereof.

The method ASTM D6248-98 for determining the amount of the vinyl groups are described under “Determination Methods”.

Still a further embodiment of the polymer composition according to the present invention, as described herein, discloses a polymer composition, wherein the polymer composition contains a total amount of vinyl groups which is B vinyl groups per 1000 carbon atoms, and B₁≤B, wherein B₁ is 0.89, when measured prior to crosslinking according to method ASTM D6248-98.

Still a further embodiment of the polymer composition is disclosed, wherein B₁ is 0.90.

In a further embodiment according to the present invention, a polymer composition, as described herein, is disclosed, wherein B₁ is 0.92.

An even further embodiment of the polymer composition is disclosed, wherein B₁ is 0.94.

Still a further embodiment of the polymer composition is disclosed, wherein B₁ is 0.95.

An even further embodiment of the polymer composition is disclosed, wherein B₁ is 1.00.

Further embodiments of the polymer composition are disclosed, wherein B₁ is 0.95, 1.00, 1.05 or 1.10.

Still further embodiments of the polymer composition are disclosed, wherein B₁ is 0.90, 0.95, 1.00, 1.05, 1.10, 1.15, 1.20, 1.25 or 1.30.

Further embodiments of the polymer composition are disclosed, wherein B₁ is 0.90, 0.95, 1.00, 1.05, 1.10, 1.15, 1.20, 1.25 or 1.30, and/or Z₂ is 0.28 or 0.26.

Even further embodiments of the polymer composition are disclosed, wherein B₁ is 1.15, 1.20, 1.25 or 1.30.

Still a further embodiment of the polymer composition is disclosed, wherein B₁ is 1.30.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein B≤B₂ and B₂ is 3.0.

Further embodiments of the polymer composition are disclosed wherein the polymer composition contains a total amount of vinyl groups which is B vinyl groups per 1000 carbon atoms, and B₁≤B≤B₂, wherein B₁ and B₂ may each be selected from any of the values given herein for B₁ and B₂, respectively.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein B₂ is 2.5.

In a particularly preferred embodiment, B₁ is 0.89 and B₂ is 3.0, even more preferably B₁ is 0.90 and B₂ is 1.5.

The polymer composition further comprises a crosslinking agent.

The crosslinking agent, for example a peroxide, is present in an amount which is Z wt %, based on the total amount (100 wt %) of the polymer composition, and Z≤Z₂, wherein Z₂ is 0.30.

In a further embodiment according to the present invention, the polymer composition, as described herein, wherein the crosslinking agent is present in an amount which is Z wt %, based on the total amount (100 wt %) of the polymer composition, and Z₁≤Z, wherein Z₁ is 0.01.

The crosslinking agent is defined herein to be any compound capable to generate radicals which can initiate a crosslinking reaction. For example, the crosslinking agent contains —O—O— bond.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the crosslinking agent comprises peroxide, e.g. a peroxide.

In a further embodiment, the crosslinking agent comprises peroxide.

In an even further embodiment, the crosslinking agent comprises a peroxide.

In a further embodiment, the crosslinking agent is a peroxide.

In further embodiments of the present invention, a polymer composition, as described herein, is disclosed, wherein Z₁ is 0.02, 0.04, 0.06 or 0.08.

Even further, embodiments of the polymer composition according to the present invention, as described herein, are disclosed, wherein Z₁ is, for example, 0.1 or 0.2 and/or Z₂ is, for example, 0.30, 0.28 or 0.26.

In a further embodiment Z₂ is 0.28 or 0.26. In still a further embodiment Z₂ is 0.28.

In an even further embodiment Z₂ is 0.26. In a further embodiment Z₂ is 0.24, 0.22 or 0.20. In still a further embodiment Z₂ is 0.24. In an even further embodiment Z₂ is 0.22. In a further embodiment Z₂ is 0.20.

In a further embodiment Z₂ is 0.29 or 0.27. In still a further embodiment Z₂ is 0.29.

In an even further embodiment Z₂ is 0.27.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, the amount Z of the crosslinking agent, for example a peroxide, is Z₂ being 0.25.

In still a further embodiment the amount Z of the crosslinking agent, for example a peroxide, is Z₂ being 0.23.

In an even further embodiment, the amount Z of the crosslinking agent, for example a peroxide, is Z₂ being 0.21.

Non-limiting examples of the crosslinking agents comprise organic peroxides, such as di-tert-amylperoxide, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3, 2,5-di(tert-butylperoxy)-2,5-dimethylhexane, tert-butylcumylperoxide, di(tert-butyl)peroxide, dicumylperoxide, butyl-4,4-bis(tert-butylperoxy)-valerate, 1,1-bis(tert-butylperoxy)-3,3,5-trimethylcyclohexane, tert-butylperoxybenzoate, dibenzoylperoxide, bis(tert butylperoxyisopropyl)benzene, 2,5-dimethyl-2,5-di(benzoylperoxy)hexane, 1,1-di(tert-butylperoxy)cyclohexane, 1,1-di(tert amylperoxy)cyclohexane, or any mixtures thereof.

In further embodiments, the crosslinking agent being a peroxide may, for example, be selected from 2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3, 2,5-di(tert-butylperoxy)-2,5-dimethylhexane, di(tert-butylperoxyisopropyl)benzene, dicumylperoxide, tert-butylcumylperoxide, di(tert-butyl)peroxide, or any mixtures thereof.

In still a further embodiment the crosslinking agent is a peroxide selected from any of dicumylperoxide, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3 and tert-butylcumylperoxide, or of any mixtures thereof.

In a further embodiment, the crosslinking agent comprises a peroxide which is dicumylperoxide.

In still a further embodiment, the crosslinking agent comprises a peroxide which is 2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3.

In even a further embodiment, the crosslinking agent comprises a peroxide which is tert-butylcumylperoxide.

In an embodiment the polymer composition comprises the crosslinking agent.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein B≤B₂ and B₂ is 3.0 and Z₁≤Z≤Z₂, wherein Z₁ is 0.01.

Further embodiments of the polymer composition are disclosed, as described herein, wherein the crosslinking agent is present in an amount which is Z wt %, based on the total amount (100 wt %) of the polymer composition, and Z₁≤Z≤Z₂, wherein Z₁ and Z₂ may each be selected from any of the values given herein for Z₁ and Z₂, respectively.

In a further embodiment according to the present invention, as described herein, Z₁ is 0.05.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Z₁ is 0.10.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Z₂ is 0.15.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Z₂ is 0.20.

In a particularly preferred embodiment, Z₁ is 0.02 and Z₂ is 0.28, even more preferably Z₁ is 0.05 and Z₂ is 0.20.

The MFR₂ is determined, prior to crosslinking, according to ISO 1133-1:2011 under 2.16 kg load and at 190° C.

In a further embodiment according to the present invention, the polymer composition, as described herein, has prior to crosslinking a melt flow rate at 2.16 kg loading (MFR₂) and at 190° C., determined, according to method ISO 1133-1:2011, which MFR₂ is A g/10 min and A≤A₂, wherein A₂ is 10.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₂ is 5.0.

In still a further embodiment of the polymer composition, A₂ is 4.0.

Still an embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₂ is 3.0.

In still a further embodiment the polymer composition according to the present invention, as described herein, is disclosed, wherein A₂ is 2.7.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₂ is 2.5.

Still an embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₂ is 2.0.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₂ is 1.7.

In still a further embodiment the polymer composition has a melt flow rate, MFR₂, which is A g/10 min and A₁≤A; wherein A₁ is 0.05.

Further embodiments of the polymer composition are disclosed which have a melt flow rate, MFR₂, which is A g/10 min and A₁≤A≤A₂; wherein A₁ and A₂ may each be selected from any of the values given herein for A₁ and A₂, respectively. Still an embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₁ is 0.10.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₁ is 0.15.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₁ is 0.20.

Still an embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.25.

A further embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.30.

An embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.35.

Still an embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.40.

A further embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.45.

An embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.50.

A further embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.55.

An embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.60.

Still an embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.65.

A further embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.70.

An embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.75.

Still an embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.80.

A further embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.85.

An embodiment according to the present invention, as described herein, is disclosed, wherein A₁ is 0.90.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₂ is 1.65.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₂ is 1.60.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₂ is 1.55.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein A₂ is 1.50.

In a particularly preferred embodiment, A₁ is 0.15 and A₂ is 3.0, even more preferably A₁ is 0.60 and A₂ is 2.5.

In one preferred embodiment the polymer composition simultaneously satisfies the following:

-   -   B₁≤B≤B₂ wherein B₁ is 0.89 and B₂ is 3.0;     -   Z₁≤Z≤Z₂ wherein Z₁ is 0.02 and Z₂ is 0.28; and     -   A₁≤A≤A₂ wherein A₁ is 0.15 and A₂ is 3;

preferably

-   -   B₁≤B≤B₂ wherein B₁ is 0.9 and B₂ is 1.5;     -   Z₁≤Z≤Z₂ wherein Z₁ is 0.05 and Z₂ is 0.20; and     -   A₁≤A≤A₂ wherein A₁ is 0.60 and A₂ is 2.5.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the polyethylene, before crosslinking, has a complex viscosity (η*) at 0.05 rad/sec, which is X Pas, and X₁≤X≤X₂,

wherein X₁ is 10000 and X₂ is 30000, and

a complex viscosity (η*) at 300 rad/sec, which is Y Pas, and Y₁≤Y≤Y₂, wherein Y₁ is 5 and Y₂ is 350, both complex viscosities (η*) are determined according to method ISO 6721-1 on stabilised samples of the polyethylene.

Further embodiments are disclosed wherein the polyethylene, before crosslinking, has a complex viscosity (η*) at 0.05 rad/sec, determined according to method ISO 6721-1 on stabilised samples of the polyethylene, which is X Pas, and X₁≤X≤X₂, wherein X₁ and X₂ may each be selected from any of the values given herein for X_(i) and X₂, respectively.

Still further embodiments are disclosed wherein the polyethylene, before crosslinking, has a complex viscosity (η*) at 300 rad/sec determined according to method ISO 6721-1 on stabilised samples of the polyethylene, which is Y Pas, and Y₁≤Y≤Y₂, wherein Y₁ and Y₂ may each be selected from any of the values given herein for Y₁ and Y₂, respectively.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 11000.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 12000.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 13000.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 14000.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 29000.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 28000.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 27000.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 26000.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 25000.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 24000.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 15000.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 16000.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 17000.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 18000.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 18100.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 18200.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 18300.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 18400.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 18500.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 18600.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 18700.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 23500.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 23000.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 22900.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 22800.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 22700.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 22600.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 22500.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 22400.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₂ is 22300.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 10.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 20.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 30.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 40.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 50.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 60.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 70.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 80.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 90.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 100.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 110.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 120.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 130.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 140.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 150.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 160.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 170.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 180.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 190.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 200.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 210.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 220.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 230.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 240.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₁ is 250.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₂ is 345.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₂ is 340.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₂ is 335.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein Y₂ is 330.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 12000 and X₂ is 28000, and wherein Y₁ is 250 and Y₂ is 330.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 13000 and X₂ is 27000, and wherein Y₁ is 240 and Y₂ is 340.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein X₁ is 13000 and X₂ is 27000, and wherein Y₁ is 250 and Y₂ is 330.

In further embodiments the polymer composition may also comprise further additive(s). Such further additive(s) comprise:

unsaturated low molecular weight compound(s), for example:

-   -   Crosslinking booster(s) mentioned herein, including any given         specific compound(s), which can contribute to the crosslinking         degree and/or to the amount of vinyl groups in the polymer         composition.     -   One or more scorch retarders (SR) which are defined herein to be         compounds that reduce the formation of scorch during extrusion         of a polymer composition, at typical extrusion temperatures         used, if compared to the same polymer composition extruded         without said compound. The scorch retarders can also contribute         to the total amount of vinyl groups in the polymer composition.

Any contribution from the unsaturated low molecular weight compound(s), for example, the crosslinking booster(s) and/or the “one or more” scorch retarders (SR) to the amount of vinyl groups in the polymer composition is also measured according to method ASTM D6248-98.

The crosslinking booster may be a compound containing at least 2, unsaturated groups, such as an aliphatic or aromatic compound, an ester, an ether, an amine, or a ketone, which contains at least 2, unsaturated group(s), such as a cyanurate, an isocyanurate, a phosphate, an ortho formate, an aliphatic or aromatic ether, or an allyl ester of benzene tricarboxylic acid. Examples of esters, ethers, amines and ketones are compounds selected from general groups of diacrylates, triacrylates, tetraacrylates, triallylcyanurate, triallylisocyanurate, 3,9-divinyl-2,4,8,10-tetra-oxaspiro[5,5]-undecane (DVS), triallyl trimellitate (TATM) or N,N,N′,N′,N″,N″-hexaallyl-1,3,5-triazine-2,4,6-triamine (HATATA), or any mixtures thereof. The crosslinking booster can be added in an amount of such crosslinking less than 2.0 wt %, for example, less than 1.5 wt %, e.g. less than 1.0 wt %, for example, less than 0.75 wt %, e.g less than 0.5 wt %, and the lower limit thereof is, for example, at least 0.05 wt %, e.g., at least 0.1 wt %, based on the weight of the polymer composition.

The scorch retarders (SR) may, e.g., be unsaturated dimers of aromatic alpha-methyl alkenyl monomers, such as 2,4-di-phenyl-4-methyl-1-pentene, substituted or unsubstituted diphenylethylene, quinone derivatives, hydroquinone derivatives, monofunctional vinyl containing esters and ethers, monocyclic hydrocarbons having at least two or more double bonds, or mixtures thereof. For example, the scorch retarder may be selected from 2,4-diphenyl-4-methyl-1-pentene, substituted or unsubstituted diphenylethylene, or mixtures thereof.

The amount of scorch retarder may, for example, be equal to, or more than, 0.005 wt %, based on the weight of the polymer composition. Further, the amount of scorch retarder may, for example, be equal to, or more than, 0.01 wt %, equal to, or more than, 0.03 wt %, or equal to, or more than, 0.04 wt %, based on the weight of the polymer composition.

Further, the amount of scorch retarder may, for example, be equal to, or less than, 2.0 wt %, e.g., equal to, or less than, 1.5 wt %, based on the weight of the polymer composition. Further, the amount of scorch retarder may, for example, be equal to, or less than, 0.8 wt %, equal to, or less than, 0.75 wt %, equal to, or less than, 0.70 wt %, or equal to, or less than, 0.60 wt %, based on the weight of the polymer composition. Moreover, the amount of scorch retarder may, for example, be equal to, or less than, 0.55 wt %, equal to, or less than, 0.50 wt %, equal to, or less than, 0.45 wt %, or equal to, or less than, 0.40 wt %, based on the weight of the polymer composition.

Still further, the amount of scorch retarder may, for example, be equal to, or less than, 0.35 wt %, e.g., equal to, or less than, 0.30 wt %, based on the weight of the polymer composition. Further, the amount of scorch retarder may, for example, be equal to, or less than, 0.25 wt %, equal to, or less than, 0.20 wt %, equal to, or less than, 0.15 wt %, or equal to, or less than, 0.10 wt %, based on the weight of the polymer composition. Moreover, the amount of scorch retarder may, for example, be equal to, or less than, 0.15 wt %, or equal to, or less than, 0.10 wt %, based on the weight of the polymer composition.

Furthermore, the amount of scorch retarder may, for example, be within the range of 0.005 to 2.0 wt %, e.g., within the range of 0.005 to 1.5 wt %, based on the weight of the polymer composition. Further exemplified ranges are e.g. from 0.01 to 0.8 wt %, 0.03 to 0.75 wt %, 0.03 to 0.70 wt %, or 0.04 to 0.60 wt %, based on the weight of the polymer composition. Moreover, exemplified ranges are e.g. from 0.01 to 0.60, to 0.55, to 0.50, to 0.45 or, alternatively, to 0.40 wt %, 0.03 to 0.0.55 or, alternatively, to 0.50 wt %, 0.03 to 0.45 or, alternatively, 0.40 wt %, or 0.04 to 0.45 or, alternatively, 0.40 wt %, based on the weight of the polymer composition.

Further, the scorch retarders (SR) may, e.g., be selected from graftable stable organic free radicals, as described in EP1699882, which include hindered amine-derived stable organic free radicals: for example, hydroxy-derivative of 2,2,6,6,-tetramethyl piperidinyl oxy (TEMPO), e.g. 4-hydroxy-TEMPO or a bis-TEMPO (for example, bis(1-oxyl-2,2,6,6-tetramethylpiperidine-4-yl)sebacate), and, for example, multi-functional molecules having at least two nitroxyl groups derived from oxo-TEMPO, 4-hydroxy-TEMPO, an ester of 4-hydroxy-TEMPO, polymer-bound TEMPO, PROXYL, DOXYL, ditertiary butyl N oxyl, dimethyl diphenylpyrrolidine-1-oxyl, or 4 phosphonoxy TEMPO.

The graftable stable organic free radicals may be, as described in EP1699882, present in an amount equal to, or more than, about 0.005 weight percent, for example, equal to, or more than, about 0.01 weight percent and equal to, or more than, about 0.03 weight percent, based on the weight of the polymer composition.

Further, the graftable stable organic free radicals may be, as described in EP1699882, present in an amount equal to, or less than, about 20.0 weight percent, for example, equal to, or less than, about 10.0 weight percent, e.g., equal to, or less than, about 5.0 weight percent, based on the weight of the polymer composition.

Furthermore, the graftable stable organic free radicals may be, as described in EP1699882, present in an amount between about 0.005 weight percent and about 20.0 weight percent, for example, between 15 about 0.01 weight percent and about 10.0 weight percent, e.g., between about 0.03 weight percent and about 5.0 weight percent, based on the weight of the polymer composition.

Moreover, such further additive(s) comprise additive(s), such as antioxidant(s), stabiliser(s), and/or processing aid(s). As an antioxidant, sterically hindered or semi-hindered phenol(s), aromatic amine(s), aliphatic sterically hindered amine(s), organic phosphate(s), thio compound(s), and mixtures thereof, can be mentioned. As further additive(s), flame retardant additive(s), water tree retardant additive(s), acid scavenger(s), filler(s) pigment(s), and voltage stabilizer(s) can be mentioned.

Examples of suitable fillers and/or pigments include TiO₂, CaCO₃, carbon black (e.g. conductive carbon black or “UV black”, i.e. a carbon black that absorbs ultraviolet radiation), huntite, mica, kaolin, aluminium hydroxide (ATH), magnesium dihydroxide (MDH), and SiO₂.

In still a further embodiment the polymer composition according to the present invention further comprises fillers and/or pigments.

Furthermore, said fillers and/or pigments may be comprised in the polymer composition according to the present invention in amounts of, for example, 0.01 to 5 wt %, e.g., 0.01 to 3 wt % or, e.g., 0.01 to 2 wt %.

The polymer composition may additionally comprise further polymer component(s) including unsaturated polymer(s) and/or polymer(s) that are not unsaturated, wherein the further polymer component(s) are different from said polyethylene.

The polymer composition can be provided in the form of a powder or pellets in any shape and size including granules. Pellets can be produced, e.g. after polymerisation of said polyethylene, in a well known manner using the conventional pelletising equipment, such as a pelletising extruder. The polymer composition may, for example, be provided in the form of pellets.

Furthermore, during the crosslinking of the polymer composition, the decomposition of the crosslinking agent in the polymer composition results in the formation of less than 130 ppm of methane, when measured according to the method for GC-Analysis, while, at the same time, a technically desirable level of crosslinking degree of the polymer composition is maintained, when measured according to the method for Hot Set Determination. The method for GC-Analysis and the method for Hot Set Determination are described further herein in the experimental part under “Determination methods”.

An embodiment according to the present invention, a polymer composition, as described herein, is disclosed, wherein decomposition of the crosslinking agent, during crosslinking of the polymer composition, results in formation of less than 130 ppm of methane, when measured according to the method for GC-Analysis.

In a further embodiment according to the present invention, a polymer composition, as described herein, is disclosed, wherein the decomposition of the crosslinking agent results in the formation of less than 125 ppm of methane.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the decomposition of the crosslinking agent results in the formation of less than 120 ppm of methane.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the decomposition of the crosslinking agent results in the formation of less than 110 ppm of methane.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the decomposition of the crosslinking agent results in the formation of less than 105 or 100 ppm of methane.

Still an embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the decomposition of the crosslinking agent results in the formation of less than 95, 90, 85 or 80 ppm of methane.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the decomposition of the crosslinking agent results in the formation of less than 85 or 80 ppm of methane.

Further, the crosslinked polymer composition has a hot set elongation, with a load of 5 N/cm², which is less than 175% at 200° C., when measured on crosslinked plaque sample according to the method for Hot Set Determination. This method is described further herein in the part relating to crosslinking and also in the experimental part under “Determination methods”.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the polymer composition is crosslinked and has a hot set elongation, with a load of 5 N/cm², which is less than 175%, when measured according to the method for Hot Set Determination.

In a further embodiment according to the present invention, the polymer composition, as described herein, has a hot set elongation, with a load of 5 N/cm², which is less than 170%, or, alternatively, is less than 160%.

Still an embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein said hot set elongation, with a load of 5 N/cm², is less than 150%.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein said hot set elongation, with a load of 5 N/cm², is less than 140%.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein said hot set elongation, with a load of 5 N/cm², is less than 130%.

An even further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein said hot set elongation, with a load of 5 N/cm², is less than 120%, or, alternatively, is less than 110%.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the crosslinked polymer composition has a hot set elongation, with a load of 5 N/cm², which is less than 100%.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the crosslinked polymer composition has a hot set elongation, with a load of 5 N/cm², which is less than 95%, or, alternatively, is less than 90%.

An embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the decomposition of the crosslinking agent results in the formation of less than 130 ppm of methane and the crosslinked polymer composition has a hot set elongation, with a load of 5 N/cm², which is less than 100%.

A further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the decomposition of the crosslinking agent results in the formation of less than 130 ppm of methane and the crosslinked polymer composition has a hot set elongation, with a load of 5 N/cm², which is less than 90%.

The Polyethylene of the Polymer Composition

In embodiments of the polymer composition, the polyethylene contains said total amount of vinyl groups which is P vinyl groups per 1000 carbon atoms, as described herein. As described herein P₁≤P or P₁≤P≤P₂.

In an embodiment of the polymer composition, the polyethylene contains said total amount of vinyl groups which is P vinyl groups per 1000 carbon atoms.

In a further embodiment of the polymer composition, the polyethylene contains the total amount of vinyl groups being P wherein P₁ is 0.88.

In a particularly preferred embodiment, P₁ is 0.89 and P₂ is 3.0, even more preferably P₁ is 0.90 and P₂ is 1.5.

In one preferred embodiment the polymer composition simultaneously satisfies the following:

-   -   P₁≤P≤P₂ wherein P₁ is 0.89 and P₂ is 3.0;     -   Z₁≤Z≤Z₂ wherein Z₁ is 0.02 and Z₂ is 0.28; and     -   A₁≤A≤A₂ wherein A₁ is 0.15 and A₂ is 3;

preferably

-   -   P₁≤P≤P₂ wherein P₁ is 0.9 and P₂ is 1.5;     -   Z₁≤Z≤Z₂ wherein Z₁ is 0.05 and Z₂ is 0.20; and     -   A₁≤A≤A₂ wherein A₁ is 0.60 and A₂ is 2.5.

The “amount of vinyl groups” means in this embodiment the “total amount of vinyl groups present in the polyethylene”. The polyethylene means herein both homopolymer, having been provided with unsaturation by a chain transfer agent, and a copolymer, wherein the unsaturation is provided by polymerising a monomer together with at least a polyunsaturated comonomer, optionally in the presence of a chain transfer agent and, also, optionally in combination with further comonomers.

In one embodiment the polyethylene is an unsaturated copolymer which, as already mentioned herein, comprises one or more polyunsaturated comonomer(s). Further, said vinyl groups (P) present in the unsaturated copolymer may originate from said polyunsaturated comonomer, a process of producing the polyethylene and, optionally, from any used chain transfer agent.

When the polyethylene of the polymer composition, is an unsaturated copolymer comprising at least one polyunsaturated comonomer, then the polyunsaturated comonomer is straight carbon chain with at least 8 carbon atoms and at least 4 carbon atoms between the non-conjugated double bonds, of which at least one is terminal.

As to suitable polymer materials for the polymer composition, said polyethylene can be any polymer having relevant features, as defined herein, for the polyethylene of the exemplified polymer composition. The polyethylene may be selected from homopolymers of polyethylene as well as copolymers of polyethylene with one or more comonomer(s). The polyethylene can be unimodal or multimodal with respect to molecular weight distribution and/or comonomer distribution, which expressions have a well known meaning.

In one embodiment, the polyethylene is a homopolymer of ethylene.

In an embodiment of the polymer composition, the polymer composition is obtained by a process comprising homopolymerisation of ethylene.

In an exemplified embodiment of the polymer composition, the polyethylene is an unsaturated copolymer of polyethylene with at least one polyunsaturated comonomer and optionally with one or more other comonomer(s).

Said unsaturated copolymer of polyethylene is an unsaturated copolymer of ethylene.

In an embodiment of the present invention, a polymer composition, as described herein, is disclosed, wherein the polyethylene is a copolymer of a monomer with at least one polyunsaturated comonomer and with zero, one or more, for example, zero, one, two or three, other comonomer(s), and wherein said total amount of vinyl groups (B) present in the polymer composition include vinyl groups originating from said at least one polyunsaturated comonomer, e.g. diene.

In an exemplified embodiment of the polymer composition, the polymer composition is obtained by a process comprising blending an unsaturated copolymer of ethylene with the crosslinking agent.

Said copolymer of ethylene may be a LDPE copolymer produced in a continuous high pressure polymerisation process, wherein ethylene is copolymerised with at least one polyunsaturated comonomer and optionally with one or more other comonomer(s), optionally in the presence of a chain transfer agent.

The optional further comonomer(s) present in the polyethylene, for example, copolymer of ethylene, is different from the “backbone” monomer and may be selected from an ethylene and higher alpha-olefin(s), e.g. C₃-C₂₀ alpha-olefin(s), for example, a cyclic alpha-olefin of 5 to 12 carbon or a straight or branched chain alpha-olefin of 3 to 12 carbon atoms, such as propylene, 1-butene, 1-hexene, 1-nonene or 1-octene, as well as, from polar comonomer(s).

In one embodiment the straight or branched chain alpha-olefin is a straight or branched chain alpha-olefin of 3 to 6 carbon atoms.

In a further embodiment the straight chain alpha-olefin is propylene.

It is well known that e.g. propylene can be used as a comonomer or as a chain transfer agent (CTA), or both, whereby it can contribute to the total amount of the vinyl groups in the polyethylene, P. Herein, when copolymerisable CTA, such as propylene, is used, the copolymerised CTA is not calculated to the comonomer content.

In an exemplified embodiment of the polymer composition, the polyethylene is an unsaturated LDPE polymer, for example, an unsaturated LDPE copolymer comprising at least one comonomer which is a polyunsaturated comonomer (referred herein as LDPE copolymer).

Further, said polyunsaturated comonomer may be a diene, for example, (1) a diene which comprises at least 8 carbon atoms, the first carbon-carbon double bond being terminal and the second carbon-carbon double bond being non-conjugated to the first one (group 1 dienes). Exemplified dienes (1) may be selected from C₈ to C₁₄ non-conjugated dienes or mixtures thereof, for example, selected from 1,7-octadiene, 1,9-decadiene, 1,11-dodecadiene, 1,13-tetradecadiene, 7-methyl-1,6-octadiene, 9-methyl-1,8-decadiene, or mixtures thereof. In a further embodiment, the diene (1) is selected from 1,7-octadiene, 1,9-decadiene, 1,11-dodecadiene, 1,13-tetradecadiene, or any mixture thereof.

A further embodiment according to the present invention of the polymer composition, as described herein, is disclosed, wherein the polyethylene is a copolymer of a monomer with at least one polyunsaturated comonomer, wherein the polyunsaturated comonomer is a straight carbon chain with at least 8 carbon atoms and at least 4 carbon atoms between the non-conjugated double bonds, of which at least one is terminal, for example, C₈ to C₁₄ non-conjugated diene, e.g. selected from 1,7-octadiene, 1,9-decadiene, 1,11-dodecadiene, 1,13-tetradecadiene, or mixtures thereof.

In a preferred embodiment the polyethylene is a copolymer of ethylene and 1,7-octadiene.

Still a further embodiment of the polymer composition according to the present invention, as described herein, is disclosed, wherein the polyethylene is an unsaturated LDPE homopolymer or copolymer produced in a continuous high pressure polymerisation process, e.g. a LDPE copolymer of ethylene with one or more polyunsaturated comonomer(s) and with zero, one or more other comonomer(s).

In addition or as an alternative to the dienes (1) listed herein, the diene may also be selected from other types of polyunsaturated dienes (2), such as from one or more siloxane compounds having the following formula (group (2) dienes):

CH₂═CH—[SiR₁R₂—O]_(n)—SiR₁R₂—CH═CH₂,

-   -   wherein n=1 to 200, and     -   R₁ and R₂, which can be the same or different, are selected from         C₁ to     -   C₄ alkyl groups and/or C₁ to C₄ alkoxy groups.

Further, R₁ and/or R₂ may, for example, be methyl, methoxy or ethoxy. Furthermore, n may, for example, be 1 to 100, e.g., 1 to 50. As an example, divinylsiloxanes, for example, α,ω-divinylsiloxane can be mentioned.

Exemplified polyunsaturated comonomers for the polyethylene are the dienes from group (1) as defined herein. The polyethylene may, for example, be a copolymer of ethylene with at least one diene selected from 1,7-octadiene, 1,9-decadiene, 1,11-dodecadiene, 1,13-tetradecadiene, or any mixture thereof, and optionally with one or more other comonomer(s). It is also exemplified that said polyethylene is the herein-mentioned unsaturated LDPE copolymer. It may comprise further comonomers, e.g. polar comonomer(s), alpha-olefin comonomer(s), non-polar comonomer(s) or any mixture thereof.

As a polar comonomer, compound(s) containing hydroxyl group(s), alkoxy group(s), carbonyl group(s), carboxyl group(s), ether group(s) or ester group(s), or a mixture thereof can used.

Further, a non-polar comonomer, is/are compound(s) not containing hydroxyl group(s), alkoxy group(s), carbonyl group(s), carboxyl group(s), ether group(s) nor ester group(s).

In a further embodiment, compounds containing carboxyl and/or ester group(s) are used and, e.g., the compound is selected from the groups of acrylate(s), methacrylate(s) or acetate(s), or any mixtures thereof.

If present in said unsaturated LDPE copolymer, the polar comonomer may, for example, be selected from the group of alkyl acrylates, alkyl methacrylates or vinyl acetate, or a mixture thereof. Further, said polar comonomers may, for example, be selected from C₁- to C₆-alkyl acrylates, C₁- to C₆-alkyl methacrylates or vinyl acetate. Still further, said polar copolymer comprises a copolymer of ethylene with C₁- to C₄-alkyl acrylate, such as methyl, ethyl, propyl or butyl acrylate, or vinyl acetate, or any mixture thereof.

The polyethylene, of the herein described polymer composition, can be prepared using i.a. any conventional polymerisation process and equipment, the conventional means as described herein for providing unsaturation and any conventional means for adjusting the MFR₂, in order to control and adjust the process conditions to achieve a desired balance between MFR₂ and amount of vinyl groups of the polymerised polymer. The unsaturated LDPE polymer as defined herein, e.g. the unsaturated LDPE copolymer, of the polymer composition is produced in continuous high pressure reactor by free radical initiated polymerisation (referred to as high pressure radical polymerisation). The usable high pressure (HP) polymerisation and the adjustment of process conditions are well known and described in the literature, and can readily be used by a skilled person to provide the herein described inventive balance. Continuous high pressure polymerisation can be performed in a tubular reactor or an autoclave reactor, e.g. in a tubular reactor. One embodiment of continuous HP process is described herein for polymerising ethylene optionally together with one or more comonomer(s), for example, at least with one or more polyunsaturated comonomer(s), in a tubular reactor to obtain a LDPE homopolymer or copolymer as defined herein. The process can be adapted to other polymers as well.

Further, the polyethylene, of the herein described polymer composition, may be produced in a high pressure reactor by free radical polymerisation (referred to as high pressure radical polymerisation). Free radical initiated polymerisation is very rapid and thus well suited for a continuous process where careful control of process parameters can be obtained by continuous monitoring and adjustments. To the high pressure radical polymerisation process there is a continuous feed of ethylene and initiator. The high pressure radical polymerisation process is preferably an autoclave or tubular process, more preferably a tubular reactor. A high pressure tubular process typically produces a polyethylene with a more narrow molecular weight distribution and with a lower degree of long chain branches and with another branching structure compared to a polyethylene produced in an autoclave process if similar process conditions are used such as similar temperature profile, similar pressure and similar initiator feed. Typically, a tubular reactor also has more favourable production economics because they have higher ethylene conversion rates.

In a further embodiment the polyethylene of the polymer composition, of the present invention, is produced in a continuous high pressure tubular reactor.

Compression:

Ethylene is fed to a compressor mainly to enable handling of high amounts of ethylene at controlled pressure and temperature. The compressors are usually a piston compressor or diaphragm compressors. The compressor is usually a series of compressors that can work in series or in parallel. Most common is 2-5 compression steps. Recycled ethylene and comonomers can be added at feasible points depending on the pressure. Temperature is typically low, usually in the range of less than 200° C. or less than 100° C. Said temperature may, for example, be less than 200° C.

Tubular Reactor:

The mixture is fed to the tubular reactor. First part of the tube is to adjust the temperature of the fed ethylene; usual temperature is 150-170° C. Then the radical initiator is added. As the radical initiator, any compound or a mixture thereof that decomposes to radicals at an elevated temperature can be used. Usable radical initiators are commercially available. The polymerisation reaction is exothermic. There can be several radical initiator injections points, e.g. 1-5 points, usually provided with separate injection pumps. Also ethylene and optional comonomer(s) can be added at any time during the process, at any zone of the tubular reactor and/or from one or more injection points, as well known. The reactor is continuously cooled e.g. by water or steam. The highest temperature is called peak temperature and the lowest temperature is called radical initiator temperature. The “lowest temperature” means herein the reaction starting temperature which is called the initiation temperature which is “lower” as evident to a skilled person.

Suitable temperatures range from 80 to 350° C. and pressure from 100 to 400 MPa. Pressure can be measured at least in the compression stage and after the tube. Temperature can be measured at several points during all steps. High temperature and high pressure generally increase output. Using various temperature profiles selected by a person skilled in the art will allow control of structure of polymer chain, i.e. Long Chain Branching and/or Short Chain branching, density, MFR, viscosity, Molecular Weight Distribution etc.

The reactor ends conventionally with a valve. The valve regulates reactor pressure and depressurizes the reaction mixture from reaction pressure to separation pressure.

Separation:

The pressure is typically reduced to approx. 10 to 45 MPa, for example to approx. 30 to 45 MPa. The polymer is separated from the unreacted products, for instance gaseous products, such as monomer or the optional comonomer(s), and most of the unreacted products are recovered. Normally low molecular compounds, i.e. wax, are removed from the gas. The pressure can further be lowered to recover and recycle the unused gaseous products, such as ethylene. The gas is usually cooled and cleaned before recycling.

Then the obtained polymer melt is normally mixed and pelletized. Optionally, or in some embodiments, additives can be added in the mixer. Further details of the production of ethylene (co)polymers by high pressure radical polymerisation can be found in the Encyclopedia of Polymer Science and Engineering, Vol. 6 (1986), pp 383-410.

The MFR₂ of the polyethylene, e.g. LDPE copolymer, can be adjusted by using e.g. chain transfer agent during the polymerisation, and/or by adjusting reaction temperature or pressure.

When the LDPE copolymer of the invention is prepared, then, as well known, the amount of vinyl groups can be adjusted by polymerising the ethylene e.g. in the presence of one or more polyunsaturated comonomer(s), chain transfer agent(s), or both, using the desired feed ratio between C₂ and polyunsaturated comonomer and/or chain transfer agent, depending on the nature and amount of carbon carbon double bonds desired for the LDPE copolymer. I.a. WO 9308222 describes a high pressure radical polymerisation of ethylene with polyunsaturated monomers, such as an α,ω-alkadienes, to increase the unsaturation of an ethylene copolymer. The non-reacted double bond(s) thus provides pendant vinyl groups to the formed polymer chain at the site, where the polyunsaturated comonomer was incorporated by polymerisation. As a result the unsaturation can be uniformly distributed along the polymer chain in random copolymerisation manner. Also e.g. WO 9635732 describes high pressure radical polymerisation of ethylene and a certain type of polyunsaturated α,ω-divinylsiloxanes. Moreover, as known, e.g. propylene can be used as a chain transfer agent to provide double bonds, whereby it can also partly be copolymerised with ethylene.

The alternative unsaturated LDPE homopolymer may be produced analogously to the herein described process conditions as the unsaturated LDPE copolymer, except that ethylene is polymerised in the presence of a chain transfer agent only.

One exemplified polyethylene, e.g. of the LDPE copolymer, of the present invention may have a density, when measured on the polyethylene according to ISO 1183-1 method A:2012, of e.g. higher than 0.860 g/cm³, higher than 0.870, higher than 0.880, higher than 0.885, higher than 0.890, higher than 0.895, higher than 0.900, higher than 0.905, higher than 0.910, or of higher than 0.915 g/cm³.

Another exemplified polyethylene, e.g. of the LDPE copolymer, of the present invention may have a density, when measured on the polyethylene according to ISO 1183-1 method A:2012, of up to 0.960 g/cm³, less than 0.955, less than 0.950, less than 0.945, less than 0.940, less than 0.935, or of less than 0.930 g/cm³.

In a further embodiment the density range, when measured on the polyethylene according to ISO 1183-1 method A:2012, is from 0.915 to 0.930 g/cm³.

Further, said unsaturated copolymer, e.g. the LDPE copolymer, of the polymer composition comprises comonomer(s) in a total amount of up to 45 wt %, e.g. of from 0.05 to 25 wt %, or e.g. from 0.1 to 15 wt %, based on the amount of the polyethylene.

An exemplified polyethylene of the polymer composition is crosslinkable.

In an exemplified embodiment the polymer composition consists of the at least one polyethylene. The polymer composition may comprise further components such as herein described additives which may be added in a mixture with a carrier polymer, i.e. in so called master batch.

In a further embodiment, the polymer composition may comprise the polyethylene, as described herein, together with the crosslinking agent and together with 0, 1, 2, 3, 4, 5, 6 or more additive(s), and wherein the polymer composition is in the form of pellets.

A further embodiment of the present invention discloses a process for producing a polymer composition as described herein, the process comprising blending the polyethylene with the crosslinking agent.

End Applications

An embodiment of the present invention provides an article obtained from process comprising use of a polymer composition as described herein, wherein the article is, for example, a cable, e.g. a power cable.

A further embodiment of the present invention provides an article, which is obtained from a process comprising use of the polymer composition as described herein.

Still a further embodiment of the present invention provides an article comprising layer(s), e.g. insulating layer(s), which is/are obtained from a polymer composition as described herein, wherein the article is, for example, a cable, e.g. a power cable.

In an embodiment of the present invention an article, e.g. a cable, is provided, wherein the cable, e.g. power the cable, comprises one layer being obtained from said polymer composition.

In a further embodiment of the present invention an article is provided, wherein said article is crosslinkable and is obtained from a process comprising use of the polymer composition as described herein.

In still a further embodiment of the present invention an article is provided, wherein said article comprises the polymer composition as described herein.

In a further embodiment of the present invention an article is provided, wherein said article is crosslinked and is obtained from a process comprising use of the polymer composition as described herein.

A further embodiment of the present invention provides an article, which is a cable, e.g. a power cable.

Further, the invention is highly suitable for W&C applications, whereby an article is e.g. a cable, which is crosslinkable and comprises one or more layers, wherein at least one layer is obtained from the polymer composition as described herein.

Furthermore, still a further embodiment of the present invention is provided, wherein said at least one layer comprises the polymer composition as described herein.

A further embodiment of the present invention provides a power cable comprising layer(s), e.g. insulating layer(s), which is/are obtained from the polymer composition as described herein.

Still a further embodiment of the present invention is provided, wherein said article is an AC power cable.

A further embodiment of the present invention is provided wherein said article is a DC power cable.

Furthermore, still a further embodiment of the present invention is provided, wherein the expression “is obtained from the polymer composition” also comprises the feature “comprises the polymer composition”.

Furthermore, the at least one layer of the cable comprising the polymer composition may, e.g., be an insulation layer.

Further, the cable of the present invention may, for example, be a power cable which comprises at least an inner semiconductive layer, an insulation layer and an outer semiconductive layer in given order, wherein at least the insulation layer is obtained from the polymer composition as described herein.

In a further embodiment the insulation layer comprises the polymer composition as described herein.

The power cable means herein a cable that transfers energy operating at any voltage. The voltage applied to the power cable can be AC, DC or transient (impulse). In an embodiment, the multi-layered article is a power cable operating at voltages higher than 6 kV.

A further embodiment of the present invention discloses a process for producing an article, as described herein, which process comprises use of a polymer composition, as described herein.

Moreover, the invention provides a process for producing the herein described article, which comprises the steps of a) forming an article, wherein the process comprises the polymer composition as described herein. Said process may, for example, comprise at least the steps of

a₀) meltmixing a polymer composition as described herein optionally together with further component(s), and

a) forming a cable obtained from the polymer composition as described herein.

A further embodiment discloses forming a cable comprising the polymer composition as described herein.

“Meltmixing” is well known blending method, wherein the polymer component(s) are mixed in an elevated temperature, which is typically above, e.g. at least 20-25° C. above, the melting or softening point of polymer component(s).

In an embodiment a cable, which comprises a conductor surrounded by one or more layers, is produced, wherein the process comprises a step of a) applying on a conductor the polymer composition, as described herein, to form at least one of said layers surrounding the conductor.

Thus in step (a) the at least one layer of said one or more layers is applied and obtained by using the polymer composition as described herein.

Also the herein exemplified cable production process may, for example, comprise at least two steps of

a₀) meltmixing said polymer composition, as described herein, optionally together with further component(s), and then

a) applying the meltmix obtained from step a₀) on a conductor to form at least one layer.

The polymer composition, as described herein, may be introduced to step a₀) of the process, e.g. in pellet form and mixing, i.e. meltmixing, is carried out in an elevated temperature which melts (or softens) the polymer material to enable processing thereof.

Further, the layers may, for example, be a) applied by (co)extrusion. The term “(co)extrusion” means herein that in case of two or more layers, said layers can be extruded in separate steps, or at least two or all of said layers can be coextruded in a same extrusion step, as well known in the art.

In one exemplified embodiment the crosslinkable polymer composition may comprise a crosslinking agent before the polymer composition is used for cable production, whereby the polyethylene and the crosslinking agent can be blended by any conventional mixing process, e.g. by addition of the crosslinking agent to a melt of a composition of polymer, e.g. in an extruder, as well as by adsorption of liquid peroxide, peroxide in liquid form or peroxide dissolved in a solvent on a solid composition of polymer, e.g. pellets thereof. Alternatively in this embodiment, the polyethylene and the crosslinking agent can be blended by any conventional mixing process. Exemplary mixing procedures include melt mixing, e.g. in an extruder, as well as adsorption of liquid peroxide, peroxide in liquid form or a peroxide dissolved in a solvent of a composition of the polymer or on pellets thereof. The obtained polymer composition of components, for example, a.o. the polyethylene and the crosslinking agent, is then used for an article, e.g. a cable, preparation process.

In another embodiment, the crosslinking agent may be added e.g. in step a₀) during the preparation of the crosslinkable article, and also forms the polymer composition of the present invention. When the crosslinking agent is added during the article preparation process, then, for example, the crosslinking agent, as described herein, is added in a liquid form at ambient temperature, or is preheated above the melting point thereof or dissolved in a carrier medium, as well known in the art.

The polymer composition of the present invention may also comprise further additive(s), or further additive(s) may be blended to the polymer composition during a preparation process of an article comprising the polymer composition.

Accordingly the process of the invention may, for example, comprise the steps of

-   -   a₀₀) providing to said step a₀) said polymer composition as         described herein, which comprises         -   at least one polyethylene, and         -   a crosslinking agent,     -   a₀) meltmixing the polymer composition optionally together with         further components, and

a) applying the meltmix obtained from step a₀) on a conductor to form at least one of said one or more cable layers.

Alternatively, the process of the invention comprises the steps of

-   -   a₀₀) providing to said step a₀) said polymer composition as         described herein, which comprises at least one polyethylene,     -   a_(00′)) adding to said polymer composition at least one         crosslinking agent,     -   a₀) meltmixing the polymer composition and the crosslinking         agent, optionally together with further components, and     -   a) applying the meltmix obtained from step a₀) on a conductor to         form at least one of said one or more cable layers.

In the exemplified process, the a₀) meltmixing of the polymer composition alone is performed in a mixer or an extruder, or in any combination thereof, at elevated temperature and, if crosslinking agent is present, then also below the subsequently used crosslinking temperature. After a₀) meltmixing, e.g. in said extruder, the resulting meltmixed layer material is then, for example, a) (co)extruded on a conductor in a manner very well known in the field. Mixers and extruders, such as single or twins screw extruders, which are used conventionally for cable preparation are suitable for the process of the invention.

The exemplified embodiment of the process provides the preparation of a crosslinkable cable, e.g. a crosslinkable power cable, wherein the process comprises a further step of b) crosslinking the at least one cable layer obtained from step a) comprising a crosslinkable polyethylene of the polymer composition, wherein the crosslinking is performed in the presence of a crosslinking agent, e.g. a peroxide.

It is understood and well known that also the other cable layers and materials thereof, if present, can be crosslinked at the same time, if desired.

Crosslinking can be performed at crosslinking conditions, typically by treatment at increased temperature, e.g. at a temperature above 140° C., e.g. above 150° C., such as within the range of 160 to 350° C., depending on the used crosslinking agent as well known in the field. Typically the crosslinking temperature is at least 20° C. higher than the temperature used in meltmixing step a₀) and can be estimated by a skilled person.

As a result a crosslinked cable is obtained comprising at least one crosslinked layer of the polymer composition of the invention.

In a further embodiment according to the present invention a polymer composition is disclosed, wherein said total amount of vinyl groups, B, originates from (beside vinyl groups originating from free radical initiated polymerisation):

i) polyunsaturated comonomer(s),

ii) chain transfer agent(s),

iii) unsaturated low molecular weight compound(s), e.g. crosslinking booster(s) and/or scorch retarder(s), or

iv) any mixture of (i) to (iii).

In general, “vinyl group” means herein CH₂═CH— moiety which can be present in any of i) to iv).

The i) polyunsaturated comonomers and ii) chain transfer agents are described herein in relation to the polyethylene of the polymer composition according to the present invention.

The iii) low molecular weight compound(s), if present, may be added into the polymer composition.

Further, the iii) low molecular weight compound(s) can, for example, be crosslinking booster(s) which may also contribute to said total amount of vinyl groups, B, of the polymer composition. The crosslinking booster(s) may be e.g. compound(s) containing at least 2, unsaturated groups, such as an aliphatic or aromatic compound, an ester, an ether, or a ketone, which contains at least 2, unsaturated group(s), such as a cyanurate, an isocyanurate, a phosphate, an ortho formate, an aliphatic or aromatic ether, or an allyl ester of benzene tricarboxylic acid. Examples of esters, ethers, amines and ketones are compounds selected from general groups of diacrylates, triacrylates, tetraacrylates, triallylcyanurate, triallylisocyanurate, 3,9-divinyl-2,4,8,10-tetra-oxaspiro[5,5]-undecane (DVS), triallyl trimellitate (TATM) or N,N,N′,N′,N″,N″-hexaallyl-1,3,5-triazine-2,4,6-triamine (HATATA), or any mixtures thereof. The crosslinking booster can be added in an amount of such crosslinking less than 2.0 wt %, for example, less than 1.5 wt %, e.g. less than 1.0 wt %, for example, less than 0.75 wt %, e.g. less than 0.5 wt %, and the lower limit thereof is, for example, at least 0.05 wt %, e.g., at least 0.1 wt %, based on the weight of the polymer composition.

Furthermore, the iii) low molecular weight compound(s) can, for example, be scorch retarder(s) (SR) which may also contribute to said total amount of vinyl groups, B, of the polymer composition.

The scorch retarders (SR) may, e.g., be, as already described herein, unsaturated dimers of aromatic alpha-methyl alkenyl monomers, such as 2,4-di-phenyl-4-methyl-1-pentene, substituted or unsubstituted diphenylethylene, quinone derivatives, hydroquinone derivatives, monofunctional vinyl containing esters and ethers, monocyclic hydrocarbons having at least two or more double bonds, or mixtures thereof. For example, the scorch retarder may be selected from 2,4-diphenyl-4-methyl-1-pentene, substituted or unsubstituted diphenylethylene, or mixtures thereof.

The amount of scorch retarder may, for example, be equal to, or more than, 0.005 wt %, based on the weight of the polymer composition. Further, the amount of scorch retarder may, for example, be equal to, or more than, 0.01 wt %, equal to, or more than, 0.03 wt %, or equal to, or more than, 0.04 wt %, based on the weight of the polymer composition.

Further, the amount of scorch retarder may, for example, be equal to, or less than, 2.0 wt %, e.g., equal to, or less than, 1.5 wt %, based on the weight of the polymer composition. Further, the amount of scorch retarder may, for example, be equal to, or less than, 0.8 wt %, equal to, or less than, 0.75 wt %, equal to, or less than, 0.70 wt %, or equal to, or less than, 0.60 wt %, based on the weight of the polymer composition. Moreover, the amount of scorch retarder may, for example, be equal to, or less than, 0.55 wt %, equal to, or less than, 0.50 wt %, equal to, or less than, 0.45 wt %, or equal to, or less than, 0.40 wt %, based on the weight of the polymer composition.

Still further, the amount of scorch retarder may, for example, be equal to, or less than, 0.35 wt %, e.g., equal to, or less than, 0.30 wt %, based on the weight of the polymer composition. Further, the amount of scorch retarder may, for example, be equal to, or less than, 0.25 wt %, equal to, or less than, 0.20 wt %, equal to, or less than, 0.15 wt %, or equal to, or less than, 0.10 wt %, based on the weight of the polymer composition. Moreover, the amount of scorch retarder may, for example, be equal to, or less than, 0.15 wt %, or equal to, or less than, 0.10 wt %, based on the weight of the polymer composition.

Furthermore, the amount of scorch retarder may, for example, be within the range of 0.005 to 2.0 wt %, e.g., within the range of 0.005 to 1.5 wt %, based on the weight of the polymer composition. Further exemplified ranges are e.g. from 0.01 to 0.8 wt %, 0.03 to 0.75 wt %, 0.03 to 0.70 wt %, or 0.04 to 0.60 wt %, based on the weight of the polymer composition. Moreover, exemplified ranges are e.g. from 0.01 to 0.60, to 0.55, to 0.50, to 0.45 or, alternatively, to 0.40 wt %, 0.03 to 0.0.55 or, alternatively, to 0.50 wt %, 0.03 to 0.45 or, alternatively, 0.40 wt %, or 0.04 to 0.45 or, alternatively, 0.40 wt %, based on the weight of the polymer composition.

Further, the scorch retarders (SR) may, e.g., also be selected from graftable stable organic free radicals, as described in EP1699882 and as also already described herein.

The polyethylene of the polymer composition may, for example, be a copolymer of monomer units with units of at least one unsaturated comonomer(s) and zero, one, two or three other comonomer(s), and comprises at least vinyl groups which originate from the polyunsaturated comonomer.

Further, the polyethylene of the polymer composition may comprise about 0.05 to about 0.10 vinyl groups per 1000 carbon atoms (C-atoms) which originate from the free radical initiated polymerisation.

In accordance with the present invention each feature in any of the herein disclosed embodiments, in any category of the present invention, may freely be combined with any feature in any of the other herein disclosed embodiments.

Determination Methods

Unless otherwise stated in the description or experimental part the following methods were used for the property determinations.

Melt Flow Rate

The melt flow rate (MFR) is determined according to method ISO 1133-1:2011 and is indicated in g/10 min. The MFR is an indication of the flowability, and hence the processability, of the polymer, here the polyethylene, or of the polymer composition. The higher the melt flow rate, the lower the viscosity of the polymer, or of the polymer composition. The MFR is determined at 190° C. for polyethylenes and may be determined at different loadings such as 2.16 kg (MFR₂) or 21.6 kg (MFR₂₁).

Density

Density is measured on the polymer, i.e. on the polyethylene, according to ISO 1183-1 method A:2012. Sample preparation is done by compression moulding in accordance with ISO 17855-2:2016.

Methods ASTM D3124-98, and ASTM D6248-98, to Determine Amount of Double Bonds in the Polymer Composition or in the Polymer, i.e. the Polyethylene

The method ASTM D6248-98 apply for determination of double bonds, both, in the polymer composition and in the polyethylene. Determination of double bonds of the polymer composition is made either on the polyethylene (to determine the paramtere P) or, alternatively, on the polymer composition (to determine the parameter B). The polymer composition and the polyethylene are, hereinafter in this method description, referred to as “the composition” and “the polymer”, respectively.

The methods ASTM D3124-98, and ASTM D6248-98, include on one hand a procedure for the determination of the amount of double bonds/1000 C-atoms which is based upon the ASTM D3124-98 method. In the ASTM D3124-98 method, a detailed description for the determination of vinylidene groups/1000 C-atoms is given based on 2,3-dimethyl-1,3-butadiene. In the ASTM D6248-98 method, detailed descriptions for the determination of vinyl and trans-vinylene groups/1000 C-atoms are given based on 1-octene and trans-3-hexene, respectively. The described sample preparation procedure therein has here been applied for the determination of vinyl groups/1000 C-atoms and trans-vinylene groups/1000 C-atoms in the present invention. The ASTM D6248-98 method suggests possible inclusion of the bromination procedure of the ASTM D3124-98 method but the samples with regard to the present invention were not brominated. We have demonstrated that the determination of vinyl groups/1000 C-atoms and trans-vinylene groups/1000 C-atoms can be done without any significant interferences even without subtraction of spectra from brominated samples. For the determination of the extinction coefficient for these two types of double bonds, the following two compounds have been used: 1-decene for vinyl and trans-4-decene for trans-vinylene, and the procedure as described in ASTM-D6248-98 was followed with above the mentioned exception.

The total amount of vinyl bonds, vinylidene bonds and trans-vinylene double bonds of “the polymer” was analysed by means of IR spectrometry and given as the amount of vinyl bonds, vinylidene bonds and trans-vinylene bonds per 1000 carbon atoms.

Further, the total amount of vinyl and trans-vinylene double bonds of “the composition”, with a possible contribution of double bonds from any used unsaturated low molecular weight compound (iii), may also be analysed by means of IR spectrometry and given as the amount of vinyl bonds, vinylidene bonds and trans-vinylene bonds per 1000 carbon atoms.

The composition or polymer to be analysed were pressed to thin films with a thickness of 0.5-1.0 mm. The actual thickness was measured. FT-IR analysis was performed on a Perkin Elmer Spectrum One. Two scans were recorded with a resolution of 4 cm⁻¹.

A base line was drawn from 980 cm⁻¹ to around 840 cm⁻¹. The peak heights were determined at around 910 cm⁻¹ for vinyl and around 965 cm⁻¹ for trans-vinylene. The amount of double bonds/1000 carbon atoms was calculated using the following formulae:

vinyl/1000 C-atoms=(14×Abs)/(13.13×L×D)

trans-vinylene/1000 C-atoms=(14×Abs)/(15.14×L×D)

-   -   wherein     -   Abs: absorbance (peak height)     -   L: film thickness in mm     -   D: density of the material (g/cm³)

The molar absorptivity, ε, i.e. 13.13 and, 15.14, respectively, in the above calculations was determined as l·mol⁻¹·mm⁻¹ via:

ε=Abs/(C×L)

where Abs is the maximum absorbance defined as peak height, C the concentration (mol·l⁻¹) and L the cell thickness (mm).

The methods ASTM D3124-98, and ASTM D6248-98, include on the other hand also a procedure to determine the molar extinction coefficient. At least three 0.18 mol·l⁻¹ solutions in carbon disulphide (CS₂) were used and the mean value of the molar extinction coefficient used.

The amount of vinyl groups originating from the polyunsaturated comonomer per 1000 carbon atoms was determined and calculated as follows:

The polymer to be analysed and a reference polymer have been produced on the same reactor, basically using the same conditions, i.e. similar peak temperatures, pressure and production rate, but with the only difference that the polyunsaturated comonomer is added to the polymer to be analysed and not added to reference polymer. The total amount of vinyl groups of each polymer was determined by FT-IR measurements, as described herein. Then, it is assumed that the base level of vinyl groups, i.e. the ones formed by the process and from chain transfer agents resulting in vinyl groups (if present), is the same for the reference polymer and the polymer to be analysed with the only exception that in the polymer to be analysed also a polyunsaturated comonomer is added to the reactor. This base level is then subtracted from the measured amount of vinyl groups in the polymer to be analysed, thereby resulting in the amount of vinyl groups/1000 C-atoms, which result from the polyunsaturated comonomer.

The Methods ASTM D3124-98, and ASTM D6248-98, Include a Calibration Procedure for Measuring the Double Bond Content of an Unsaturated Low Molecular Weight Compound (iii), if Present (Referred Below as Compound)

The molar absorptivity for Compound (e.g. a crosslinking booster or a scorch retarder compound as exemplified in the description) can be determined with said methods according to ASTM D6248-98. At least three solutions of the Compound in CS₂ (carbon disulfide) are prepared. The used concentrations of the solutions are close to 0.18 mol/1. The solutions are analysed with FTIR and scanned with resolution 4 cm⁻¹ in a liquid cell with path length 0.1 mm. The maximum intensity of the absorbance peak that relates to the unsaturated moiety of the Compound(s) (each type of carbon-carbon double bonds present) is measured.

The molar absorptivity, ε, in l·mol⁻¹·mm⁻¹ for each solution and type of double bond is calculated using the following equation:

ε=(1/CL)×Abs

C=concentration of each type of carbon-carbon double bond to be measured, mol/1

L=cell thickness, mm

Abs=maximum absorbance (peak height) of the peak of each type of carbon-carbon double bond to be measured, mol/1.

The average of the molar absorptivity, E, for each type of double bond is calculated. Further, the average molar absorptivity, E, of each type of carbon-carbon double bond can then be used for the calculation of the concentration of double bonds in the reference polymer and the polymer samples to be analysed.

Rheology, Dynamic (Viscosity) Method ISO 6721-1:

Dynamic rheological properties of the polymer, here the polyethylene, or of the polymer composition (also measured on the polyethylene) may be determined using a controlled stress rheometer, using a parallel-plate geometry (25 mm diameter) and a gap of 1.8 mm between upper and bottom plates. Previous to test, samples need to be stabilized by dry blending pellets together with 0.25-0.3% Irganox B225.

Irganox B 225 is a blend of 50% Irganox 1010, Pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate), CAS-no. 6683-19-8 and 50% lrgafos 168, Tris(2,4-di-tert-butylphenyl) phosphite, CAS-no. 31570-04-4. Note that to add an antioxidant, here Irganox B225, is normally not the standard procedure of method ISO 6721-1.

Frequency sweep test, i.e. the “Rheology, dynamic (Viscosity) method”, was performed according to the ISO standard method, ISO 6721-1 with an angular frequency range from 500 to 0.02 rad/s. All experiments were conducted under nitrogen atmosphere at a constant temperature of 190° C. and strain within the linear viscoelastic region. During analysis, storage modulus (G″), loss modulus (G″), complex modulus (G*) and complex viscosity (η*) were recorded and plotted versus frequency (w). The measured values of complex viscosity (η*) at angular frequency of 0.05, 100 and 300 rad/s are taken from test. The abbreviation of these parameters are η*_(0.05), η*₁₀₀ and η*₃₀₀ respectively.

The zero viscosity η*₀ value is calculated using Carreau-Yasuda model. For cases when the use of this model for the estimation of the Zero shear viscosity is not recommendable a rotational shear test at low shear rate is performed. This test is limited to a shear rate range of 0.001 to 1 s⁻¹ and a temperature of 190° C.

Preparation of Crosslinked Plaque, i.e. the Method for Crosslinking Plaque:

-   -   Preparation of crosslinked plaque when using dicumyl peroxide         (DCP) or tert-butylcumyl-peroxide (TBCP) as peroxide, i.e. the         method for crosslinking plaque     -   The crosslinked plaque is prepared from of pellets of the test         polymer composition, i.e. the polymer composition according to         the present invention and the comparative polymer composition,         which were compression moulded using the following conditions:         First the pellets are melted at 120° C. for 1 min under a         pressure of 61 N/cm². Then the temperature is increased to         180° C. at a rate of 18 K/min and at the same time the pressure         is increased to 614 N/cm². The temperature is maintained at         180° C. for 10 min. The plaques then become crosslinked by means         of the peroxide present in the polymer composition. The total         crosslinking time is 14 minutes which includes the time for         increasing the temperature from 120 to 180° C. After completed         crosslinking the crosslinked plaques, i.e. the crosslinked         polymer composition according to the present invention and the         crosslinked comparative polymer composition, is cooled to room         temperature with a cooling rate of 15 K/min still under         pressure. The final thickness of the plaques is 1.5 mm.     -   Preparation of crosslinked plaque when using         2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3, i.e. Trigonox®         145-E85, (T145E85) as peroxide, i.e. the method for crosslinking         plaque     -   The crosslinked plaque is prepared from of pellets of the test         polymer composition, i.e. the polymer composition according to         the present invention and the comparative polymer composition,         which were compression moulded using the following conditions:         First the pellets are melted at 120° C. for 1 min under a         pressure of 61 N/cm². Then the temperature is increased to         180° C. at a rate of 18 K/min and at the same time the pressure         is increased to 614 N/cm². The temperature is maintained at         180° C. for 20 min. The plaques then become crosslinked by means         of the peroxide present in the polymer composition. The total         crosslinking time is 24 minutes which includes the time for         increasing the temperature from 120 to 180° C. After completed         crosslinking the crosslinked plaques, i.e. the crosslinked         polymer composition according to the present invention and the         crosslinked comparative polymer composition, is cooled to room         temperature with a cooling rate of 15 K/min still under         pressure. The final thickness of the plaques is 1.5 mm.

Gas Chromatography (GC)-Analysis Protocol, i.e. Method for GC-Analysis

-   -   GC-Analysis protocol (plaque), i.e. method for GC-Analysis     -   The volatile peroxide decomposition products, herein methane         (CH₄), content is given in ppm (weight) and is determined by gas         chromatography (GC) from a crosslinked sample of the polymer         composition according to the present invention and of the         comparative polymer composition. Said crosslinking has been         performed as described in the method for crosslinking plaque.     -   A sample specimen with a thickness of 1.5 mm and with a weight         of 1 g is cut from the middle of the crosslinked plaque, i.e.         the crosslinked polymer composition according to the present         invention and the crosslinked comparative polymer composition,         directly after the crosslinking step (i.e. in the method for         crosslinking plaque) is complete. The obtained sample is placed         in a 120 ml head space bottle with an aluminium crimp cup with         teflon seal and heat treated at 60° C. for 1.5 h to equilibrate         any gaseous volatiles present in said sample. Then 0.2 ml of the         gas captured in the sample bottle is injected into the gas         chromatograph, wherein the presence and content of the         volatiles, e.g. methane, which are desired to be measured is         analysed. Double samples are analysed and the reported methane         content value is an average of both analyses. The instrument         used herein was an Agilent GC 7890A with an Al₂O₃/Na₂SO₄— column         with the dimensions 0.53 mm×50 m and a film thickness of 10 μm,         supplied by Plot Ultimetal. Helium was used as carrier gas and         FID detection was used.

Method for Hot Set Determination

-   -   Hot Set Method for sample from crosslinked plaques     -   The hot set elongation, as well as the permanent deformation         were determined on samples taken from crosslinked plaques, i.e.         the crosslinked polymer composition according to the present         invention and of the crosslinked comparative polymer         composition. These properties were determined according to IEC         60811-507:2012. In the hot set test, a dumbbell of the tested         material is equipped with a weight corresponding to 5 N/cm².         First of all the specimen is marked with reference lines. From         the middle of the specimen, two reference lines (one on each         side) are made. The distance between the two lines, L0 is 20 mm.         This specimen is put into an oven at 200° C. with the weight         corresponding to 5 N/cm² and after 15 minutes, the hot set         elongation is measured as follow. The distance between reference         lines after 15 min at 200° C. is called L1 and is measured. Then         the elongation after 15 min is calculated as follows: hot set         elongation (%)=((L1*100)/L0)−100. Subsequently, the weight is         removed and the sample is allowed to relax for 5 minutes at         200° C. Then, the sample is taken out from the oven and is         cooled down to room temperature. After cooling, the distance L2         between the 2 reference lines is measured and the permanent         deformation is calculated as follow: permanent deformation         (%)=(L2*100)/L0)−100.     -   The crosslinked plaques were prepared as described under         Preparation of crosslinked plaque, i.e. the method for         crosslinking plaque, and the dumbbells specimens are prepared         from a 1.5 mm thick crosslinked plaque according to ISO         527-2/5A:2012.

Experimental Part

EXAMPLES

The Polyethylene

The polyethylenes are all low density polyethylenes polymerised in a continuous high pressure tubular reactor.

Polymer 1: Poly(ethylene-co-1,7-octadiene) polymer with 1.36 vinyl groups/1000 carbon atoms (C), Density=922.4 kg/m³, MFR₂=1.13 g/10 min, i.e. polyethylene of the polymer composition in accordance with the present invention

Ethylene with recycled CTA was compressed in a 5-stage precompressor and a 2-stage hyper compressor with intermediate cooling to reach initial reaction pressure of ca 2800 bar. The total compressor throughput was ca 30 tons/hour. In the compressor area approximately 0.3 kg/hour of propion aldehyde (PA, CAS number: 123-38-6) was added together with approximately 43 kg propylene/hour as chain transfer agents to maintain an MFR₂ of 1.13 g/10 min. Here also 1,7-octadiene was added to the reactor in amount of 132 kg/h. The compressed mixture was heated to 155° C. in a preheating section of a front feed three-zone tubular reactor with an inner diameter of ca 40 mm and a total length of 1200 meters. A mixture of commercially available peroxide radical initiators dissolved in isododecane was injected just after the preheater in an amount sufficient for the exothermal polymerisation reaction to reach peak temperatures of ca 279° C. after which it was cooled to approximately 206° C. The subsequent 2^(nd) and 3^(rd) peak reaction temperatures were 272° C. and 245° C. respectively with a cooling in between to 217° C. The reaction mixture was depressurised by a kick valve, cooled and the resulting polymer 1 was separated from unreacted gas.

Polymer 2: Poly (ethylene-co-1,7-octadiene) polymer with 0.89 vinyl groups/1000 C, Density=923.7 kg/m³, MFR₂=0.92 g/10 min, i.e. polyethylene of the polymer composition in accordance with the present invention

Ethylene with recycled CTA was compressed in a 5-stage precompressor and a 2-stage hyper compressor with intermediate cooling to reach initial reaction pressure of ca 2800 bar. The total compressor throughput was ca 30 tons/hour. In the compressor area approximately 3.8 kg/hour of propion aldehyde (PA, CAS number: 123-38-6) was added as chain transfer agent to maintain an MFR₂ of 0.92 g/10 min. Here also 1,7-octadiene was added to the reactor in amount of 89 kg/h. The compressed mixture was heated to 162° C. in a preheating section of a front feed three-zone tubular reactor with an inner diameter of ca 40 mm and a total length of 1200 meters. A mixture of commercially available peroxide radical initiators dissolved in isododecane was injected just after the preheater in an amount sufficient for the exothermal polymerisation reaction to reach peak temperatures of ca 286° C. after which it was cooled to approximately 231° C. The subsequent 2^(nd) and 3^(rd) peak reaction temperatures were 274° C. and 248° C. respectively with a cooling in between to 222° C. The reaction mixture was depressurised by a kick valve, cooled and the resulting polymer 2 was separated from unreacted gas.

Polymer 3: Poly (ethylene-co-1,7-octadiene) polymer with 1.34 vinyl groups/1000 C, Density=924.9 kg/m³, MFR₂=1.46 g/10 min, i.e. polyethylene of the polymer composition in accordance with the present invention

Ethylene with recycled CTA was compressed in a 5-stage precompressor and a 2-stage hyper compressor with intermediate cooling to reach initial reaction pressure of ca 2800 bar. The total compressor throughput was ca 30 tons/hour. In the compressor area approximately 3.9 kg/hour of propion aldehyde (PA, CAS number: 123-38-6) was added as chain transfer agent to maintain an MFR₂ of 1.46 g/10 min. Here also 1,7-octadiene was added to the reactor in amount of 148 kg/h. The compressed mixture was heated to 159° C. in a preheating section of a front feed three-zone tubular reactor with an inner diameter of ca 40 mm and a total length of 1200 meters. A mixture of commercially available peroxide radical initiators dissolved in isododecane was injected just after the preheater in an amount sufficient for the exothermal polymerisation reaction to reach peak temperatures of ca 273° C. after which it was cooled to approximately 207° C. The subsequent 2^(nd) and 3^(rd) peak reaction temperatures were 257° C. and 226° C. respectively with a cooling in between to 209° C. The reaction mixture was depressurised by a kick valve, cooled and the resulting polymer 3 was separated from unreacted gas.

Polymer 4: Poly (ethylene-co-1,7-octadiene) polymer with 0.94 vinyl groups/1000 C, Density=922.3 kg/m³, MFR₂=1.94 g/10 min, i.e. polyethylene of the polymer composition in accordance with the present invention

Ethylene with recycled CTA was compressed in a 5-stage precompressor and a 2-stage hyper compressor with intermediate cooling to reach initial reaction pressure of ca 2900 bar. The total compressor throughput was ca 30 tons/hour. In the compressor area approximately 0.4 kg/hour of propion aldehyde (PA, CAS number: 123-38-6) was added together with approximately 117 kg propylene/hour as chain transfer agents to maintain an MFR₂ of 1.91 g/10 min. Here also 1,7-octadiene was added to the reactor in amount of 77 kg/h. The compressed mixture was heated to 162° C. in a preheating section of a front feed three-zone tubular reactor with an inner diameter of ca 40 mm and a total length of 1200 meters. A mixture of commercially available peroxide radical initiators dissolved in isododecane was injected just after the preheater in an amount sufficient for the exothermal polymerisation reaction to reach peak temperatures of ca 267° C. after which it was cooled to approximately 205° C. The subsequent 2^(nd) and 3^(rd) peak reaction temperatures were 260° C. and 237° C. respectively with a cooling in between to 213° C. The reaction mixture was depressurised by a kick valve, cooled and the resulting polymer 4 was separated from unreacted gas.

Polymer of Comparative example 1 (Polymer 5: Poly (ethylene-co-1,7-octadiene) polymer with 0.82 vinyl groups/1000 C, Density=not measured kg/m³, MFR₂=2.1 g/10 min), i.e. polyethylene of comparative polymer composition

Purified ethylene was liquefied by compression and cooling to a pressure of 90 bars and a temperature of −30° C. and split up into to two equal streams of roughly 14 tons/hour each. The CTA (methyl ethyl ketone (MEK)), air and a commercial peroxide radical initiator dissolved in a solvent were added to the two liquid ethylene streams in individual amounts. 1,7-octadiene as a comonomer was added to the reactor in amount of 190 kg/h. The two mixtures were separately pumped through an array of 4 intensifiers to reach pressures of 2200-2300 bars and exit temperatures of around 40° C. These two streams were respectively fed to the front (zone 1) (50%) and side (zone 2) (50%) of a splitfeed two-zone tubular reactor. The inner diameters and lengths of the two reactor zones were 32 mm and 200 m for zone 1 and 38 mm and 400 m for zone 2. MEK was added in amounts of 115 kg/h to the front stream to maintain a MFR2 of around 2.1 g/10 min. The front feed stream was passed through a heating section to reach a temperature sufficient for the exothermal polymerisation reaction to start. The reaction reached peak temperatures were 253° C. and 290° C. in the first and second zones, respectively. The side feed stream cooled the reaction to an initiation temperature of the second zone of 165° C.

Air and peroxide solution was added to the two streams in enough amounts to reach the target peak temperatures. The reaction mixture was depressurized by product valve, cooled and polymer was separated from unreacted gas. The obtained polymer had Vinyl groups in amount of 0.82/1000 C and MFR2=2.1 g/10 min.

Polymer of Comparative example 2—Polymer 6: Poly (ethylene-co-1,7-octadiene) polymer with 0.86 vinyl groups/1000 C, Density=not measured kg/m³, MFR₂=3.1 g/10 min, i.e. polyethylene of comparative polymer composition

Ethylene with recycled CTA was compressed in a 5-stage precompressor and a 2-stage hyper compressor with intermediate cooling to reach initial reaction pressure of ca 3000 bar. The total compressor throughput was ca 30 tons/hour. In the compressor area approximately 121 kg propylene/hour was added as chain transfer agents to maintain an MFR₂ of 3.1 g/10 min. Here also 1,7-octadiene was added to the reactor in amount of 57 kg/h. The compressed mixture was heated to 165° C. in a preheating section of a front feed three-zone tubular reactor with an inner diameter of ca 40 mm and a total length of 1200 meters. A mixture of commercially available peroxide radical initiators dissolved in isododecane was injected just after the preheater in an amount sufficient for the exothermal polymerisation reaction to reach peak temperatures of ca 283° C. after which it was cooled to approximately 225° C. The subsequent 2^(nd) and 3^(rd) peak reaction temperatures were 283° C. and 267° C. respectively with a cooling in between to 235° C. The reaction mixture was depressurised by a kick valve, cooled and polymer was separated from unreacted gas.

Polymer of Comparative example 3—Polymer 7: Poly (ethylene-co-1,7-octadiene) polymer with 0.77 vinyl groups/1000 C, Density=922.1 kg/m³, MFR₂=1.82 g/10 min), i.e. polyethylene of comparative polymer composition

Ethylene with recycled CTA was compressed in a 5-stage precompressor and a 2-stage hyper compressor with intermediate cooling to reach initial reaction pressure of ca 2900 bar. The total compressor throughput was ca 30 tons/hour. In the compressor area approximately 0.8 kg/hour of propion aldehyde (PA, CAS number: 123-38-6) was added together with approximately 123 kg propylene/hour as chain transfer agents to maintain an MFR₂ of 1.82 g/10 min. Here also 1,7-octadiene was added to the reactor in amount of 55 kg/h. The compressed mixture was heated to 163° C. in a preheating section of a front feed three-zone tubular reactor with an inner diameter of ca 40 mm and a total length of 1200 meters. A mixture of commercially available peroxide radical initiators dissolved in isododecane was injected just after the preheater in an amount sufficient for the exothermal polymerisation reaction to reach peak temperatures of ca 274° C. after which it was cooled to approximately 204° C. The subsequent 2^(nd) and 3^(rd) peak reaction temperatures were 261° C. and 244° C. respectively with a cooling in between to 216° C. The reaction mixture was depressurised by a kick valve, cooled and polymer was separated from unreacted gas.

Polymer of Comparative example 4—Polymer 8: Poly (ethylene-co-1,7-octadiene) polymer with 0.58 vinyl groups/1000 C, Density=922.1 kg/m³, MFR₂=1.75 g/10 min, i.e. polyethylene of comparative polymer composition

Ethylene with recycled CTA was compressed in a 5-stage precompressor and a 2-stage hyper compressor with intermediate cooling to reach initial reaction pressure of ca 2900 bar. The total compressor throughput was ca 30 tons/hour. In the compressor area approximately 1.6 kg/hour of propion aldehyde (PA, CAS number: 123-38-6) was added together with approximately 123 kg propylene/hour as chain transfer agents to maintain an MFR₂ of 1.75 g/10 min. Here also 1,7-octadiene was added to the reactor in amount of 34 kg/h. The compressed mixture was heated to 164° C. in a preheating section of a front feed three-zone tubular reactor with an inner diameter of ca 40 mm and a total length of 1200 meters. A mixture of commercially available peroxide radical initiators dissolved in isododecane was injected just after the preheater in an amount sufficient for the exothermal polymerisation reaction to reach peak temperatures of ca 276° C. after which it was cooled to approximately 200° C. The subsequent 2^(nd) and 3^(rd) peak reaction temperatures were 266° C. and 251° C. respectively with a cooling in between to 219° C. The reaction mixture was depressurised by a kick valve, cooled and polymer was separated from unreacted gas.

Polymer of Comparative example 5—Polymer 9: Poly (ethylene-co-1,7-octadiene) polymer with 0.71 vinyl groups/1000 C, Density=922.3 kg/m³, MFR₂=0.68 g/10 min, i.e. polyethylene of comparative polymer composition

Ethylene with recycled CTA was compressed in a 5-stage precompressor and a 2-stage hyper compressor with intermediate cooling to reach initial reaction pressure of ca 2900 bar. The total compressor throughput was ca 30 tons/hour. In the compressor area approximately 1.2 kg/hour of propion aldehyde (PA, CAS number: 123-38-6) was added together with approximately 87 kg propylene/hour as chain transfer agents to maintain an MFR₂ of 0.68 g/10 min. Here also 1,7-octadiene was added to the reactor in amount of 56 kg/h. The compressed mixture was heated to 164° C. in a preheating section of a front feed three-zone tubular reactor with an inner diameter of ca 40 mm and a total length of 1200 meters. A mixture of commercially available peroxide radical initiators dissolved in isododecane was injected just after the preheater in an amount sufficient for the exothermal polymerisation reaction to reach peak temperatures of ca 277° C. after which it was cooled to approximately 206° C. The subsequent 2^(nd) and 3^(rd) peak reaction temperatures were 270° C. and 249° C. respectively with a cooling in between to 217° C. The reaction mixture was depressurised by a kick valve, cooled and polymer was separated from unreacted gas.

The Polymer Composition

Formulations, i.e. the polymer composition of the present invention, using the polyethylene, as described herein, and no antioxidant, and also comparative examples, have been prepared on lab scale and compared, see Table 1. The crosslinking agent was added to the polyethylene by distributing the crosslinking agent (crosslinking agent is in a liquid form) at 70° C. onto the polyethylene pellets. The wet pellets were kept at 80° C. until the pellets became dry. The amount of crosslinking agent, e.g. peroxide, for example, DCP, was selected for each base resin so that about the same crosslinking degree as measured by the method for Hot Set Determination (with a load of 5 N/cm²) was achieved.

For hot set and methane measurements, 1.5 mm thick plaques were compression molded and crosslinked at 180° C. as described in the determination method under ‘preparation of crosslinked plaques, i.e. method for crosslinking plaques’. Methane was measured directly after crosslinking on 2 samples as described in determination method under ‘GC-analysis protocol (plaque), i.e. method for GC-Analysis’ and the reported value is an average of the 2 measurements. Hot set was measured on 3 samples at 200° C. with a load of 5 N/cm² as described in determination method under “Hot Set method for sample from a crosslinked plaque”.

TABLE 1 Inv. 1 Inv. 2 Inv. 3 Inv 4. Polymer Polymer 1 Polymer 2 Polymer 3 Polymer 4 Vinyl (P) 1.36 0.89 1.34 0.94 MFR₂ (g/10 min) 1.13 0.92 1.46 1.94 DCP (wt %) 0.15 0.2 0.15 0.2 Hot Set elongation (%) 49.2 38.4 38.3 69.6 Methane (ppm) 77 99 53 98 Comp. 1 Comp. 2 Comp. 3 Comp. 4 Comp. 5 Polymer Polymer 5 Polymer 6 Polymer 7 Polymer 8 Polymer 9 Vinyl (P) 0.82 0.86 0.77 0.58 0.71 MFR₂ (g/10 min) 2.1 3.1 1.82 1.75 0.68 DCP (wt %) 0.3 0.3 0.3 0.6 0.4 Hot Set elongation (%) 33.5 44.9 39 22.7 21.1 Methane (ppm) 132 117 147 269 177

The examples surprisingly show that the polymer composition of the present invention, obtained from the polyethylene, reach excellent crosslinking levels (<100% hot set elongation) while forming <130 ppm of methane. The comparative examples all form more than 130 ppm of methane when crosslinked to a technically equivalent level. Thus, polymer compositions of the present invention, wherein the polymer composition contains a total amount of vinyl groups which is B vinyl groups per 1000 carbon atoms and comprises a crosslinking agent in an amount which is Z wt %, are especially suitable for end applications where there is a need of a system combining a sufficiently crosslinked system with the simultaneous formation of little volatile decomposition products, typically methane. Accordingly, a sufficiently crosslinked system is surprisingly achieved even when a comparatively small amount of crosslinking agent, for example, peroxide, e.g., DCP, is used in accordance with the present invention in the polymer composition containing a total amount of vinyl groups which is B vinyl groups per 1000 carbon atoms. Thus, with comparatively low amount of DCP used, i.e. the crosslinking agent in an amount of Z≤Z₂, wherein Z₂ is 0.30, surprisingly sufficient crosslinking levels measured by hot set (<100% hot set elongation) are achieved by the polymer compostions of the present invention. In contrast, the comparative polymer compositions, containing a lower total amount of vinyl groups, need at least 0.3 wt % of the crosslinking agent, here DCP, to achieve sufficient crosslinking levels leading to formation of more volatile decomposition products, typically methane. 

1. A polymer composition comprising: a polyethylene and a crosslinking agent, characterized in that: the polymer composition contains a total amount of vinyl groups which is B vinyl groups per 1000 carbon atoms, and B₁≤B, wherein B₁ is 0.88, when measured prior to crosslinking according to method ASTM D6248-98; and the crosslinking agent is present in an amount which is Z wt %, based on the total amount (100 wt %) of the polymer composition, and Z≤Z₂, wherein Z₂ is 0.30.
 2. The polymer composition of claim 1, wherein the polyethylene is unsaturated or saturated.
 3. The polymer composition of claim 1, wherein decomposition of the crosslinking agent, during crosslinking of the polymer composition, results in formation of less than 130 ppm of methane, when measured according to the method for GC-Analysis.
 4. The polymer composition of claim 1, wherein the polymer composition is crosslinked and has a hot set elongation, with a load of 5 N/cm², which is less than 175%, when measured according to the method for Hot Set Determination.
 5. The polymer composition of claim 1, wherein the polyethylene is an unsaturated LDPE polymer.
 6. The polymer composition claim 1, wherein the polyethylene is a copolymer of: a monomer, at least one polyunsaturated comonomer, and zero or one or more other comonomer(s), and wherein said total amount of vinyl groups (B) present in the polymer composition include vinyl groups originating from said at least one polyunsaturated comonomer, e.g. diene.
 7. The polymer composition of claim 1, wherein the polyethylene is a copolymer of a monomer with at least one polyunsaturated comonomer, wherein the polyunsaturated comonomer is a straight carbon chain with at least 8 carbon atoms, at least two non-conjugated double bonds of which at least one is terminal, and at least 4 carbon atoms between the non-conjugated double bonds, for example, a C₈ to C₁₄ non-conjugated diene, e.g. selected from 1,7-octadiene, 1,9-decadiene, 1,11-dodecadiene, 1,13-tetradecadiene, or mixtures thereof.
 8. The polymer composition of claim 1, wherein the polyethylene is a copolymer of ethylene and 1,7-octadiene.
 9. The polymer composition of claim 1, wherein the polyethylene is a low density polyethylene (LDPE) homopolymer or copolymer, e.g. a LDPE copolymer of ethylene with one or more polyunsaturated comonomer(s) and with zero or one or more other comonomer(s).
 10. The polymer composition of claim 1, wherein said polyethylene, before crosslinking, has: a complex viscosity (η*) at 0.05 rad/sec, which is X Pas, and X₁≤X≤X₂, wherein X₁ is 10000 and X2 is 30000, and a complex viscosity (η*) at 300 rad/sec, which is Y Pas, and Y₁≤Y≤Y₂, wherein Y₁ is 5 and Y₂ is 350, wherein both complex viscosities (η′) are determined according to method ISO 6721-1 on stabilized samples of the polyethylene.
 11. The polymer composition of claim 1, wherein: B₁ is 0.90, 0.95, 1.00, 1.05, 1.10, 1.15, 1.20, 1.25 or 1.30, and/or Z₂ is 0.28 or 0.26.
 12. The polymer composition of claim 1, wherein: B≤B2 and B2 is 3.0, and Z₁≤Z≤Z₂, wherein Z₁ is 0.01.
 13. The polymer composition of claim 1, wherein the polyethylene contains a total amount of vinyl groups which is P vinyl groups per 1000 carbon atoms, wherein P₁≤P≤P₂ and, P₁ is 0.89 and P₂ is 3.0, preferably wherein P₁ is 0.90 and P₂ is 1.5.
 14. The polymer composition of claim 13, wherein the polymer composition simultaneously satisfies the following: P₁≤P≤P₂ wherein P₁ is 0.89 and P₂ is 3.0; Z₁≤Z≤Z₂ wherein Z₁ is 0.02 and Z₂ is 0.28; and wherein the polyethylene has a melt flow rate MFR₂ which is A g/10 min and A₁≤A≤A₂ wherein A₁ is 0.15 and A₂ is 3.0.
 15. The polymer composition of claim 13, wherein the polymer composition simultaneously satisfies the following: P₁<P≤P₂ wherein P₁ is 0.9 and P₂ is 1.5; Z₁≤Z≤Z₂ wherein Z₁ is 0.05 and Z₂ is 0.20; and wherein the polyethylene has a melt flow rate MFR₂ which is A g/10 min and A₁≤A≤A₂ wherein A₁ is 0.60 and A₂ is 2.5.
 16. The polymer composition of claim 1, wherein the crosslinking agent comprises a peroxide.
 17. An article comprising the polymer composition of claim 1, wherein the article is, for example, a cable.
 18. The article of claim 17, wherein the article comprises layer(s), e.g. insulating layer(s), which is/are obtained from the polymer composition, wherein the article is, for example, a cable.
 19. The article of claim 17 which is a power cable.
 20. A process for producing the polymer composition of claim 1, the process comprising blending the polyethylene with the crosslinking agent.
 21. A process for producing the article of claim 17, wherein the process comprises using the polymer composition to produce the article.
 22. The process of claim 21, wherein said article is a power cable and wherein said process comprises the steps of: a₀) meltmixing the polymer composition, optionally together with further components; and a) applying the meltmix obtained from step a₀) on a conductor to form at least one cable layer.
 23. The process of claim 22, wherein said article is a crosslinked power cable and wherein said process further comprises the step of: b) crosslinking the at least one cable layer obtained from step a). 